Ford - E 150 Van - Workshop Manual - 1985 - 1985

Factory Workshop Manual Make Ford Model E 150 Van Engine and year V8-302 5.0L (1985) 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 (V8-302 5.0L (1985)) 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 > There are 4 additional entries Code 11 - 20: Testing and Inspection 11 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 8 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 9 Key On Engine Running (KOER) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 10 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 14 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 11 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 12 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 16 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 13 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 17 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 14 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 18 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 15 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries Code 21 - 30: Testing and Inspection 21 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 20 Key On Engine Running (KOER) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 21 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 22 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 22 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 23 Key On Engine Running (KOER) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 24 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 25 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 26 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 24 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 27 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 28 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 25 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 29 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 26 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 30 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 2 additional entries > Page 31 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries Code 41 - 50: Testing and Inspection 41 Key On Engine Running (KOER) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 36 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 37 Key On Engine Running (KOER) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 38 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 43 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 39 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 40 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 45 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 41 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 46 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 42 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 47 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 43 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 48 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > There are 4 additional entries > Page 44 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries Code 51 - 60: Testing and Inspection 51 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 49 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 52 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 50 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 53 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 51 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 52 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 54 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 53 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 54 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 55 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 55 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 56 Key On Engine Running (KOER) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 57 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 56 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 58 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 59 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 58 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > There are 3 additional entries > Page 60 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries Code 61 - 70: Testing and Inspection 61 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 65 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 63 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 66 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 67 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 64 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 68 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 69 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 65 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 70 Key On Engine Running (KOER) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 71 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 66 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 72 Key On Engine Off (KOEO) Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 73 Continuous Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 67 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 74 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 68 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > There are 3 additional entries > Page 75 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 71 - 80, ( 72 73 74 75 76 77 78 79 ) > System Information > System Diagnosis > There are 2 additional entries Code 71 - 80: Testing and Inspection 72 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 73 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 71 - 80, ( 72 73 74 75 76 77 78 79 ) > System Information > System Diagnosis > There are 2 additional entries > Page 80 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 74 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 71 - 80, ( 72 73 74 75 76 77 78 79 ) > System Information > System Diagnosis > There are 2 additional entries > Page 81 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 75 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 71 - 80, ( 72 73 74 75 76 77 78 79 ) > System Information > System Diagnosis > There are 2 additional entries > Page 82 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 76 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 71 - 80, ( 72 73 74 75 76 77 78 79 ) > System Information > System Diagnosis > There are 2 additional entries > Page 83 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 77 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 71 - 80, ( 72 73 74 75 76 77 78 79 ) > System Information > System Diagnosis > There are 2 additional entries > Page 84 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86 87 88 89 ) > System Information > System Diagnosis > There are 4 additional entries Code 81 - 90: Testing and Inspection 81 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 82 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86 87 88 89 ) > System Information > System Diagnosis > There are 4 additional entries > Page 89 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 83 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86 87 88 89 ) > System Information > System Diagnosis > There are 4 additional entries > Page 90 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 84 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86 87 88 89 ) > System Information > System Diagnosis > There are 4 additional entries > Page 91 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 85 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86 87 88 89 ) > System Information > System Diagnosis > There are 4 additional entries > Page 92 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 86 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86 87 88 89 ) > System Information > System Diagnosis > There are 4 additional entries > Page 93 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 87 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86 87 88 89 ) > System Information > System Diagnosis > There are 4 additional entries > Page 94 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 88 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86 87 88 89 ) > System Information > System Diagnosis > There are 4 additional entries > Page 95 Key On Engine Off (KOEO) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 91 - 100, ( 92 93 94 95 96 97 98 99 ) > System Information > System Diagnosis > There are 4 additional entries Code 91 - 100: Testing and Inspection 91 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 92 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 91 - 100, ( 92 93 94 95 96 97 98 99 ) > System Information > System Diagnosis > There are 4 additional entries > Page 100 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 93 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 91 - 100, ( 92 93 94 95 96 97 98 99 ) > System Information > System Diagnosis > There are 4 additional entries > Page 101 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 94 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 91 - 100, ( 92 93 94 95 96 97 98 99 ) > System Information > System Diagnosis > There are 4 additional entries > Page 102 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 95 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 91 - 100, ( 92 93 94 95 96 97 98 99 ) > System Information > System Diagnosis > There are 4 additional entries > Page 103 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 96 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 91 - 100, ( 92 93 94 95 96 97 98 99 ) > System Information > System Diagnosis > There are 4 additional entries > Page 104 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 97 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 91 - 100, ( 92 93 94 95 96 97 98 99 ) > System Information > System Diagnosis > There are 4 additional entries > Page 105 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection 98 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 91 - 100, ( 92 93 94 95 96 97 98 99 ) > System Information > System Diagnosis > There are 4 additional entries > Page 106 Key On Engine Running (KOER) Codes For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 116 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations LH Side Of Dash LH Corner Of Engine Compartment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Headlamp Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 126 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 127 Fig. 30 Headlamp Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 131 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 132 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 133 Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 134 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Engine Control Module: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 148 Engine Control Module: Locations Under right side of instrument panel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 151 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 152 Fig. 133 EEC-IV connector terminal identification. V8-302 & 351 FBC E Series Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 153 Engine Control Module: Description and Operation Fig. 6 Electronic control assembly The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration assembly, Fig. 6. The processor receives input signals from the various sensors. The information obtained is used by the processor to activate engine control systems to obtain optimum emission control and performance. The calibration assembly is a permanent memory device that contains information. The processor applies the sensor inputs to the stored information to determine when and how long the various control systems should be applied. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 157 Main Relay (Computer/Fuel System): Description and Operation Fig. 12 EEC relay type, system application & relay locations EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine applications. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations EGR Control Module: Locations Behind LH Side Of Instrument Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 178 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Locations Fuel Shut-off Solenoid Relay: Locations LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 185 Main Relay (Computer/Fuel System): Description and Operation Fig. 12 EEC relay type, system application & relay locations EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine applications. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 861125 > Jun > 86 > Engine - Cranks/No Start/Stalls At Idle Ignition Control Module: Customer Interest Engine - Cranks/No Start/Stalls At Idle Article No. 86-11-25 STALL IDLE ALL EEC IV WITH TFI NO START - ENGINE CRANKS ALL EEC IV WITH TFI FORD 1984-86 ALL WITH EEC IV LINCOLN-MERCURY 1984-86 ALL WITH EEC IV Low mileage vehicles may experience an intermittent no start or stall at idle. This concern can be experienced on all 1986 production vehicles or on vehicles that have had a TFI IV Ignition Module Service replaced using part number E3EF-12A297-AlA. If an internal short circuit occurs in some recently manufactured TFI IV Ignition Modules (part number suffix A1A), the Hall sensor may become shorted to ground. At the moment of short, the EEC processor will not receive a PIP signal and the vehicle will not start or may stall at idle. The concern has been isolated to TFIIV Ignition Modules with a part number that contains the A1A suffix and a manufacturing date code of 5FOl (85 June 01) through 6D17 (86 April 17). The date code is heat stamped on the module connector shroud. 1. Follow normal Shop Manual, Volume H service procedures. NOTE: This concern can be an intermittent condition and Intermittent Diagnostic Procedures may have to be followed. 2. If replacement of the TFI IV Ignition Module is indicated, assure that service replacement part contains a part number with a suffix of A2A or one with a suffix of A1A and a manufacturing date code before 5FOl or after 6D17. PART NUMBER PART NAME CLASS E43Z-12A297-A TFI Ignition Module A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 1265OD15 TIME: 1.0 Hr. - 1.9L EFI 0.9 Hr. -All others DLR. CODING: Basic Part No. 12A297 - Code: N2, N9, Pl Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: Customer Interest Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 203 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 204 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure Ignition Control Module: All Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 210 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 211 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 216 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 217 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 218 TFI-IV Part 2 Test 3 Stator - TFI Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 219 TFI-IV Part 2 Test 4 & 5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 220 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 221 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 222 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 223 TFI-IV Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 224 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 225 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 226 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 227 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 228 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 229 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 230 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 231 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 232 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 233 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 234 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 235 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 236 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 237 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 238 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 861125 > Jun > 86 > Engine - Cranks/No Start/Stalls At Idle Ignition Control Module: All Technical Service Bulletins Engine - Cranks/No Start/Stalls At Idle Article No. 86-11-25 STALL IDLE ALL EEC IV WITH TFI NO START - ENGINE CRANKS ALL EEC IV WITH TFI FORD 1984-86 ALL WITH EEC IV LINCOLN-MERCURY 1984-86 ALL WITH EEC IV Low mileage vehicles may experience an intermittent no start or stall at idle. This concern can be experienced on all 1986 production vehicles or on vehicles that have had a TFI IV Ignition Module Service replaced using part number E3EF-12A297-AlA. If an internal short circuit occurs in some recently manufactured TFI IV Ignition Modules (part number suffix A1A), the Hall sensor may become shorted to ground. At the moment of short, the EEC processor will not receive a PIP signal and the vehicle will not start or may stall at idle. The concern has been isolated to TFIIV Ignition Modules with a part number that contains the A1A suffix and a manufacturing date code of 5FOl (85 June 01) through 6D17 (86 April 17). The date code is heat stamped on the module connector shroud. 1. Follow normal Shop Manual, Volume H service procedures. NOTE: This concern can be an intermittent condition and Intermittent Diagnostic Procedures may have to be followed. 2. If replacement of the TFI IV Ignition Module is indicated, assure that service replacement part contains a part number with a suffix of A2A or one with a suffix of A1A and a manufacturing date code before 5FOl or after 6D17. PART NUMBER PART NAME CLASS E43Z-12A297-A TFI Ignition Module A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 1265OD15 TIME: 1.0 Hr. - 1.9L EFI 0.9 Hr. -All others DLR. CODING: Basic Part No. 12A297 - Code: N2, N9, Pl Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: All Technical Service Bulletins Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 255 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 256 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Ignition Control Module: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure Ignition Control Module: All Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 266 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 267 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 272 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 273 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 274 TFI-IV Part 2 Test 3 Stator - TFI Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 275 TFI-IV Part 2 Test 4 & 5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 276 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 277 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 278 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 279 TFI-IV Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 280 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 281 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 282 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 283 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 284 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 285 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 286 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 287 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 288 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 289 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 290 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 291 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 292 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 293 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 294 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Ignition Control Module: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 303 Component Locations - RH Side Of Engine TFI-IV Ignition Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 304 Ignition Control Module: Description and Operation Thick Film Ignition Module The TFI IV ignition module, Fig. 14, has six connector pins at the wiring harness that supplies the following signals: Run Crank (start) Tach (coil) PIP (crankshaft position to ECA) Spark output (SPOUT from ECA) Internal ground from the ECA to the distributor Ignition System The TFI IV module supplies the spark to the distributor through the ignition coil and calculates the duration. It receives its control signal from the ECA (SPOUT) Fig. 29. NOTE: Some later models use a remote module (Closed Bowl Distributors/CBD). It is located in the engine compartment (Refer to "COMPONENT LOCATIONS"). The operation is essentially the same with the exception of the CBD has a wiring harness between the ignition module and the distributor. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 305 Ignition Control Module: Service and Repair Open Bowl Distributor 1. Remove distributor cap and adapter. Position cap and wires aside. 2. Disconnect TFI wiring. 3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type hold-down bolt, if equipped. 4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2. 5. Pull right side of module down distributor mounting flange and then back up to disengage module terminals from connector in distributor base. Module may then be pulled toward flange and away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI module toward distributor flange, as pins at distributor/module connector will break otherwise. 6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease D7AZ-19A331-A, or equivalent. 7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly toward distributor bowl and securely engage 3 distributor connector pins. 8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs. 9. Install distributor on engine. 10. Install distributor cap and adapter. 11. Connect TFI wiring. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 306 12. Check and, if necessary adjust engine timing according to decal. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations On RH front fender Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 320 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 321 Windshield Washer Relay: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 322 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 330 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 331 Wiper Relay: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 332 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Brake Fluid Pressure Sensor/Switch: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Technical Service Bulletins > Page 343 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 352 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 353 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine coolant temperature (ECT) sensor The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 369 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 370 Cruise Control Switch: Electrical Diagrams Horn & Speed Control Wiring Circuit (Part 1 of 2) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Horn & Speed Control Wiring Circuit (Part 2 of 2) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 372 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 373 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Auxiliary Blower Switch > Page 382 Blower Motor Switch: Locations Front Blower Switch LH Side Of Control Assembly Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Inside Doors Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention > Page 394 Fuel Gauge Sender: Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention > Page 395 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Auxiliary Tank Fuel Gauge Sender Fuel Gauge Sender: Locations Auxiliary Tank Fuel Gauge Sender Attached To Rear Fuel Tank Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Auxiliary Tank Fuel Gauge Sender > Page 398 Fuel Gauge Sender: Locations Fuel Gauge Sender Attached To Rear Fuel Tank Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Manual Transmission Backup Lamp Switch: Locations Manual Transmission Attached To Shifter Assembly Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Manual Transmission > Page 407 Backup Lamp Switch: Locations 3-Speed Manual Transmission Near Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 411 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Inside Doors Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 419 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 420 Fig. 21 Exterior Lamp (Hazard, Stop & Turn) Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 426 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 427 Fig. 30 Headlamp Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision Headlamp Switch: Technical Service Bulletins Headlamp Light Switch - Schematic Revision Article No. 91-11B-35 06/14/91 ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1981 - PAGES 40 AND 41 EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1982 - PAGE 40 - EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1984 - PAGE 34 - EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1985 - PAGE 34 - EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED LIGHT TRUCK: 1981 F-150-350 SERIES 1981-82 BRONCO 1984-85 ECONOLINE ISSUE: The connections of Exterior Lights (Marker, Park, License) to the Light Switch are inaccurately shown in the schematics of the following Electrical/Vacuum Troubleshooting Manuals: Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 432 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 433 ^ 1981 Bronco/F-Series Pages 40 and 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 434 ^ 1982 Bronco/F-Series Page 40 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 435 ^ 1984 Econoline Page 34 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 436 ^ 1985 Econoline Page 34 ACTION: Refer to the pages in this TSB article for the revised schematics. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 437 OASIS CODES: 290000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Page 438 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 444 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 445 Fig. 21 Exterior Lamp (Hazard, Stop & Turn) Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 446 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, then translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor constantly monitors air temperature entering the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 455 Barometric Pressure Sensor: Locations RH Fender Apron At Wheel Well Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation Fig. 19 Ignition barometric pressure switch. 1984-87 1984---87 This switch, Fig. 19, controls spark timing and/or other electrical devices according to barometric pressure changes. Calibration resistors in the switch assembly cause the ignition module to vary the spark timing. Spark timing is advanced for vehicle operation above a predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some switch assemblies control both spark timing and another device while other switch assemblies control only one or the other. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing Fig. 43 Ignition barometric pressure switch resistance chart. 1985---87 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 465 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 469 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 470 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine coolant temperature (ECT) sensor The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 475 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 480 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 481 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 482 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 483 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 484 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 485 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 486 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 487 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 488 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 489 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 490 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 491 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 492 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 493 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 494 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 495 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 496 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 497 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 498 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 499 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 500 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 501 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 502 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 503 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 504 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 505 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 506 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 507 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 508 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 509 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 510 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 511 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 512 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 513 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > Component Locations EGR Valve Position Sensor: Component Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > Component Locations > Page 516 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 520 Intake Air Temperature Sensor: Description and Operation Fig. 2 Air charge temperature (ACT) sensor This sensor, Fig. 2, provides the EFI system with air/fuel mixture temperature information. The air charge temperature sensor is used both as a density corrector to air flow calculation and to proportion the cold enrichment fuel flow. This sensor is similar in construction to the engine coolant temperature sensor and is mounted on an intake manifold runner or on the air cleaner. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Manifold Pressure/Vacuum Sensor: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service > Page 528 Manifold Pressure/Vacuum Sensor: Technical Service Bulletins EEC IV MAP Sensor - New Part Numbers/Applications Article No. 85-12-17 MAP SENSOR - EEC IV - NEW PART NUMBERS/APPLICATIONS FORD 1984-85 MUSTANG, LTD, TEMPO, THUNDERBIRD, CROWN VICTORIA LINCOLN-MERCURY 1984-85 CAPRI, MARQUIS, TOPAZ, COUGAR, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN LIGHT TRUCK 1984-85 RANGER, BRONCO II, E150/250, F150/250, BRONCO New MAP sensor part numbers have recently been released. The MAP sensor formerly referred to as the Yellow Dot MAP is now identified with part number E43Z-9F479-B. The Yellow Dot is no longer used for identification. The MAP sensor used for 3.8L CFI-SD applications will be identified as E5SZ-9F479-A. The chart lists the correct MAP sensor to the correct EEC IV application. PART NUMBER PART NAME CLASS E5SZ-9F479-A MAP Sensor C E43Z-9F479-B MAP Sensor A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 529 MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 530 Manifold Pressure/Vacuum Sensor: Locations On right front fender well. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 535 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 536 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 537 Oxygen Sensor: Description and Operation Fig. 8 Exhaust gas oxygen (EGO) sensor The exhaust gas oxygen sensor supplies the ECA with a signal which indicates either a rich or lean condition during engine operation. The sensor is threaded into the center of the exhaust manifold on 4-140 and 6-300 engines, threaded into the rear of left and right exhaust manifold assemblies on V6-171 engine or threaded into the rear right exhaust manifold assembly on V8-302 and 351 engine, Fig. 8. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Power Steering Pressure Switch: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Close Switch > Component Information > Description and Operation Throttle Full Close Switch: Description and Operation The idle tracking switch, is a mechanically operated electric switch held open by the throttle linkage when the throttle is closed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 549 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 550 OASIS CODES: 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 551 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 552 THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 553 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box > Page 556 Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > Page 557 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect throttle position sensor electrical connector. 3. Scribe a reference mark across edge of sensor and to throttle body to ensure correct position during installation. 4. Remove two sensor attaching screws, then the sensor and gasket. 5. Reverse procedure to install, noting the following: a. Slide the throttle position sensor rotary tangs into position over throttle shaft blade, then rotate sensor clockwise to align scribe marks. b. Torque sensor attaching screws to 11 - 16 inch lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vacuum Switch > Component Information > Locations Vacuum Switch: Locations RH Fender Apron At Wheel Well Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications VEHICLE SPEED SENSOR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 564 Vehicle Speed Sensor: Locations At LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 567 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 573 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 574 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 575 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 576 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 577 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 578 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 579 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 580 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 581 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 582 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 583 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 584 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 585 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 586 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 587 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 588 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 589 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 590 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 591 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 592 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 593 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 594 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 595 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 596 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 597 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 598 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 599 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 600 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 601 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 602 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 603 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 604 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 605 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 606 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations EGR Valve Position Sensor: Component Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations > Page 609 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: All Technical Service Bulletins Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 618 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: Customer Interest Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 624 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, then translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor constantly monitors air temperature entering the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > Tank Selector Relay Fuel Tank Selector Switch: Locations Tank Selector Relay Left Rear Corner Of Engine Compartment (next to fuel cut-off relay). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > Tank Selector Relay > Page 633 Fuel Tank Selector Switch: Locations Fuel Tank Selector Switch LH Side Of I/P Near Fuse Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations Under I/P Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 639 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Description and Operation Throttle Full Close Switch: Description and Operation The idle tracking switch, is a mechanically operated electric switch held open by the throttle linkage when the throttle is closed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 647 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 648 OASIS CODES: 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 649 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 650 THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 651 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box > Page 654 Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > Page 655 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect throttle position sensor electrical connector. 3. Scribe a reference mark across edge of sensor and to throttle body to ensure correct position during installation. 4. Remove two sensor attaching screws, then the sensor and gasket. 5. Reverse procedure to install, noting the following: a. Slide the throttle position sensor rotary tangs into position over throttle shaft blade, then rotate sensor clockwise to align scribe marks. b. Torque sensor attaching screws to 11 - 16 inch lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 661 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 666 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure Hall Effect Sensor: Technical Service Bulletins Distributor Stator - Replacement Procedure Article No. 85-4-21 DISTRIBUTOR UNIVERSAL - ALL - STATOR REPLACEMENT FORD 1983-1985 ESCORT, EXP, TEMPO, CROWN VICTORIA, MUSTANG, THUNDERBIRD, LTD LINCOLN-MERCURY 1983-1985 LYNX, TOPAZ, CAPRI, COUGAR, MARQUIS, GRAND MARQUIS, LINCOLN, CONTINENTAL, MARK VII LIGHT TRUCK 1984-1985 BRONCO II, 1983-1985 RANGER, 1985 F-100 THRU F-250, 1984-1985 ECONOLINE The stator assembly (-12A112-) is now a serviceable component for the above vehicles. The procedures to be used when servicing the stator assembly are as follows: 1.6L EFI and 1.6L EFI T/C DISTRIBUTOR W/TFI STATOR ASSEMBLY REPLACEMENT Removal 1. Using a screwdriver, remove the distributor cap and position it and the attached wires aside so as not to interfere with work area. 2. Disconnect the TFI module from the harness. 3. Remove the distributor from the engine block. 4. Remove the rotor. 5. Remove the drive coupling spring with a small screwdriver or ice pick. Take care not to damage the drive coupling or spring. 6. a. Using an air hose, blow dirt and oil from the drive end of the distributor. b. Put a small paint dot on the drive coupling and the shaft to note orientation for re-assembly. Figure 31 - Distributor Support Tool c. Place the distributor support tool (Figure 31) in a vise and tighten or open the vise jaws wide enough to let pin drop out of the coupling but not so wide that the coupling is not supported. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 671 d. Line-up the drive pin with the slot in the base. 7. With someone holding the distributor steady on the support tool or vise, use a 5/32 inch diameter drift and hammer to drive the pin out of the shaft. 8. Remove the distributor from the fixture. Remove the drive coupling from the fixture and place aside for re-assembly. 9. Before removing the shaft from the base, check for burrs on the end of the shaft and especially around the drive pin hole. If burrs are present, polish the shaft with emery paper and wipe clean before removing the shaft from the base to prevent damage to the lip seal and bushing in the base. 10. After assuring that there are no burrs, remove shaft assembly by gently pulling up on the shaft plate. 11. Remove the two screws holding the module to the base. 12. Remove the module. Wipe grease from the base and module, keeping surfaces free of dirt. 13. Remove the octane rod retaining screw. 14. Remove the octane rod assembly. 15. Remove the two screws retaining the stator connector in the bowl of the distributor. (Retain the screws for re-assembly.) 16. Remove the stator assembly from the top of the bowl, by gently lifting up. 17. Inspect the base bushing for wear or signs of excess heat concentration, replace the complete distributor assembly if damaged. 18. Inspect the shaft oil seal for tears or cuts; replace the complete distributor assembly if oil seal is damaged. 19. Carefully check the spring retainer that holds the shaft oil seal against the shaft - it must be present and have no kinks or breaks. Replace spring if necessary. 20. Inspect the base "O" ring for cuts or damage and replace the "O" ring if necessary. 21. Inspect base casting for cracks and wear. Replace complete distributor assembly if damage is found. Re-assembly and Installation 1. Place the stator over the bushing and press down to seat. 2. Place the stator connector in position - tab should fit in the notch on the base and the fastening eyelets should be aligned with their screw holes. 3. Position the wires away from moving parts. 4. Reinstall the two stator screws and torque to specification (25-35 in.lbs.). 5. With the seal on the octane rod, insert in holes. Reinstall the octane rod through the base octane rod hole. 6. Place the end of the octane rod onto the same post as the original stator only (one post should easily fit in the octane rod hole). 7. Reinstall the octane rod screw and torque to specification (25-35 in.lbs.). 8. Wipe the back of the module and the distributor module mounting face free of all dirt. 9. Apply grease (No. WA10) to back of the module and spread evenly (thin, even coverage). 10. Turn the distributor base upside down so that the stator connector is in full view. 11. Insert the module, being sure that the three module pins are inserted into the stator connector. 12. Fully seat the module into the connector and against the base. 13. Reinstall the module screws and torque to specification (25-35 in.lbs.). 14. Apply a light coat of M2C162A oil to the distributor shaft below the armature. NOTE: Do not over-lubricate. 15. Insert the shaft assembly through the base bushing. 16. Place the drive coupling over the shaft and line up the paint dots that were made during disassembly. Start the pin into the drive coupling and shaft. 17. With someone holding the distributor steady on the support tool or vise, drive the pin into the shaft until the end of the pin is flush with the step in the drive coupling. 18. Check for free movement of the drive coupling on the pin and verify that the pin does not extend beyond the step in the coupling in either direction. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 672 19. Remove the distributor from the fixture and check for free rotation. 20. Install the drive coupling spring in the groove on the drive coupling. 21. Install the distributor assembly in the engine. 22. Install the distributor cap and rotor. 23. Install the TFI module connector. UNIVERSAL DISTRIBUTOR W/EEC (OTHER THAN 1.6L) STATOR ASSEMBLY REPLACEMENT NOTE: Do not attempt to replace the stator without an arbor press. Removal 1. Using a screwdriver, remove the distributor cap, position the cap and wires aside so as not to interfere with the work area. - Remove TFI module connector. 2. Remove distributor from block per the distributor removal procedure. 3. Remove rotor. 4. Remove the two screws holding the TFI module to the base. 5. Remove the module, wipe the grease from the base and module, keeping the surfaces free of dirt. 6. If the distributor uses the push-on rotor, remove the two screws holding the armature and remove the armature. NOTE: Hold the gear to loosen the armature screws, do not hold the armature. 7. To ease re-assembly, mark with a felt tip pen, the armature, gear and collar if present (Refer to the following chart.) to note orientation. 8. Remove and discard pins in gear and collar if present (Refer to chart.). Figure 32 - Bearing Removal Tool 9. Invert the distributor and place in the Axle Bearing/Seal Plate (Tool D84L-950-A) and press off the gear using the Bearing Removal Tool (T75L-1165-B) as shown in Figure 32. 10. Deburr and polish shaft with emery paper and wipe such that the shaft slides out freely from distributor base. 11. Remove shaft assembly. 12. Remove thrust washer from distributor shaft and retain. 13. Remove octane rod retaining screw and retain. 14. Remove octane rod assembly and retain. GEAR GEAR THRUST ROLL PIN COLLAR ENGINE GEAR PIN WASHER EXTRUSION COLLAR PIN 2.3L HSC 67555-S FLUSH Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 673 2.3L OHC 67555-S FLUSH 2.8L 67575-S FLUSH 3.8L 67555-S FLUSH X 67555-S 4.9L 67775-S2 X EXTRUDE EVENLY, BOTH SIDES 5.0L 67555-S FLUSH X 67555-S 6.1L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 7.0L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 7.5L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 15. Remove two stator assembly screws and retain. 16. Remove stator assembly from top of bowl. 17. Inspect base bushing for wear or signs of excess heat concentration, replace complete distributor assembly if damaged. 18. Inspect base "O" ring for cuts or damage and replace "O" ring if necessary. 19. Inspect base for cracks and wear. Replace complete distributor assembly if damage is found. Re-assembly and Installation 1. Place the stator assembly over the bushing and press down to seat. 2. Place the stator connector in position - tab should fit in notch on base and fastening eyelets aligned with screw holes. 3. Position wires away from moving parts. 4. Install the two stator screws and torque to specification (25-35 in.lbs.). 5. Reinstall the octane rod, inserting rod through the base hole. 6. Place end of octane rod onto the same post as the original stator. Only one post should easily fit in rod hole. 7. Firmly seat octane rod seal into housing. 8. Reinstall the octane rod screw and torque to specification (25-35 in./lbs.). 9. If required, reinstall the thrust washer on top of the bushing. 10. Apply a light coat of ESF-M2C70-A to the distributor shaft below the armature. 11. Insert the shaft through the base bushing. 12. Place the collar, if required, over the shaft and line up mark on armature and collar to aid alignment with original drill hole. Use a drift punch to assure proper alignment. NOTE: Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, the collar may be 180 degrees out of alignment on the shaft. Rotate the collar on the shaft one half rotation and recheck. 13. Insert new roll pin (Part No. 67555-S) through collar and shaft. Pin should be flush with both sides of collar when seated. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 674 Figure 33 - Push On Rotor Figure 34 - Screw Down Rotor 14. If the distributor uses a push-on rotor, place a 1/2 inch deep well socket over the shaft (Figure 33), invert and place on arbor plate. 14a. If the distributor uses a screw-down rotor, invert and place on arbor plate (Figure 34). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 675 Figure 35 - Press Gear 15. Place the distributor gear on the shaft and line up the mark on the armature and gear. NOTE: The hole in the shaft and gear must be lined up as accurately as possible to assure ease of roll pin insertion. 16. Place a 5/8 inch deep well socket over the shaft and gear (Figure 35) and press gear to align with original drill hole. NOTE: If the gear holes do not align, the gear must be removed and repressed on. A drift punch will not align the holes. As in the collar, the holes should align. 17. Insert new roll pin (Refer to chart following Step 7 in the Removal Procedure) through gear and shaft. Pin should have proper extrusion, as referenced in same chart. 18. If the armature was removed, replace and torque screws to 25-35 in.lbs. 19. Check distributor for free movement over full rotation of shaft. NOTE: If the armature hits the stator; replace the entire distributor. 20. Wipe back of module and distributor module mounting face free of all dirt. 21. Apply grease (No. WA10) to the back of the module and spread evenly (thin, even coverage). 22. Turn the distributor base upside down such that the stator connector is in full view. 23. Insert the module and watch that the three module pins are inserted into the stator connector. Fully seat the module into the connector and against base. 24. Reinstall two module screws and torque to specification (25-35 in.lbs.). 25. Reinstall the distributor into block per distributor replacement procedure. 26. Connect TFI module to wiring harness. 27. Replace rotor and torque screws to specification. 28. Replace cap and torque screws to specification. 29. Retime engine. PART NUMBER PART NAME CLASS 67555-S Pin BS 67775-S2 Pin RS E3ZZ-12A112-C Stator A OTHER APPLICABLE ARTICLES: None Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 676 WARRANTY STATUS: "INFORMATION ONLY" OPERATION: STATOR REPLACE 12112D1 TIME: 1.6L Engine 0.6 HR. All Others 0.5 HR. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 677 Hall Effect Sensor: Technical Service Bulletins Engine - No Start/Idles Rough/Knock When Cold Article No. 85-7-11 (Supercedes Article No. 85-4-20) 04/04/85 NO START - ALL EEC IV IDLE ROUGH - ALL EEC IV - COLD SPARK KNOCK - ALL EEC IV COLD FORD: 1984-85 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, LTD, CROWN VICTORIA LINCOLN-MERCURY: 1984-85 LYNX, LN7 TOPAZ, CAPRI, COUGAR, MARQUIS, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK: 1984-85 BRONCO II; 1983, 84, 85 RANGER; 1984-85 F100 THRU F-250; 1984-85 ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 678 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 679 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 680 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 681 This article is being republished to revise Test 5. The above concerns can be caused by the distributor Hall Effect sensor. When the above concerns occur only at cold temperatures and the engine starts and runs satisfactorily when warm, use the first diagnostic procedure. If the concern is no start, use the second procedure. If a T.F.I. is removed from the distributor and the stator connector is soft or mushy, replace the stator. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" TFI Module Side of the SPOUT Connector Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 682 Terminal Voltage Measurement Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 683 Hall Effect Sensor: Description and Operation Profile Ignition Pickup The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA. PIP Sensor COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator, Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the output is high. When the signal is high the output is low. This output then goes to the Schmitt trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 684 PIP Signal Operation OPERATION The output signal to the Darlington amplifier is high when the window (on the armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington amplifier (switch on). Hall Effect Sensor In other words when one of the windows or openings is in the gap between the Hall device and the permanent magnet, the field stays strong and the voltage is high since the magnetic path is complete from the magnet, through the Hall device, and back to the magnet. In this case the switch is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the TFI module if the SPOUT signal from the ECA is lost. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 685 Signature PIP SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature profile ignition pickup signal. The regular type armature used for the PIP signal has the same size tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors. This system is used on cars and trucks where the ECA needs to know when to pulse certain injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the No. 1 cylinder needs to be supplied with fuel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 694 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 700 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 701 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 721 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 727 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Page 728 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 732 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Power Steering Pressure Switch: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations On Driver's Door Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 748 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 749 Windshield Washer Switch: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 750 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 756 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 757 Wiper Switch: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 758 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 759 Wiper Switch: Testing and Inspection Fig. 4 Wiper Switch Continuity Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 760 Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 761 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 762 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Alignment: Customer Interest Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull Alignment: Customer Interest Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 776 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 777 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 778 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 779 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Alignment: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Alignment: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Alignment: All Technical Service Bulletins Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 801 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 802 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 803 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 804 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Alignment: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Alignment: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 818 Alignment: By Symptom Technical Service Bulletin # 86622 Date: 860326 Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 819 TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 820 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 821 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 822 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 823 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 824 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 825 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 826 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 827 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 828 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 829 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 # 86622 Date: 860326 Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 830 OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Camber Alignment: Specifications Camber Note: Side to side caster readings must be within 5/8 (degrees), when vehicle riding height is within 1/8 inch side to side. Ride Height 4.25 in -3/4 to + 1/2 deg 4.5 in -1/4 to +1 1/8 deg 4.75 in +3/8 to +1 5/8 deg 5 in +7/8 to +2 1/4 deg 5.25 in +1 3/8 to +2 5/8 deg 5.5 in +1 3/4 to +3 deg 5.75 in +2 1/4 to +3 5/8 deg 6 in +2 3/4 to +4 deg Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Camber > Page 833 Alignment: Specifications Caster Note: Side to side caster readings must be wintin 1 1/2 (degrees), when vehicle riding height is within 1/8 inch side to side. Ride Height 3.8 in +7 1/2 to +9 1/2 deg 4.05 in +7 to +9 deg 4.3 in +6 1/4 to +8 1/4 deg 4.55 in +5 1/2 to +7 1/2 deg 4.8 in +5 to +7 deg 5.05 in +4 1/2 to +6 1/2 deg 5.3 in +3/4 to +5 3/4 deg 5.55 in +3 3/4 to +5 3/4 deg Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Camber > Page 834 Alignment: Specifications Toe Toe In .................................................................................................................................................. ........................................................................ 1/32 in Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 835 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 836 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Carburetor Fuel Pressure: Specifications Carburetor 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Carburetor > Page 842 Fuel Pressure: Specifications Fuel Injection FUEL SYSTEM SPECIFICATIONS Pressure Key On Engine Off ............................................................................................................................... ................................................... 35-45 psi Engine Idling .................................................................... ....................................................................................................................... 28-38 psi Volume A minimum of 170 ml (5.6 oz) in 10 seconds. WARNING: Fuel supply lines will remain pressurized for some period of time after the engine is shut off. Before opening the fuel system, relieve the fuel pressure. FUEL PRESSURE RELIEF PROCEDURE - Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch, or the in-line high pressure fuel pump. - Crank engine for about ten seconds. NOTE: Engine may start and run for a short time. If so, crank engine an additional five seconds after engine stalls. - Reconnect the electrical connector that was disconnected in the first step. - Disconnect negative battery cable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 843 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments Fig. 1 Propane enrichment specifications Refer to Propane Enrichment Chart, Fig. 1, when adjusting. 1. Apply parking brake, block wheels, disconnect automatic brake release, if equipped, and plug vacuum connection. 2. Connect suitable tachometer to engine. 3. If vehicle is equipped with hot idle compensator (HIC), ensure HIC is in closed position and remains closed throughout test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to ensure HIC is closed. 4. On 1983 models except V8-302 engine with 2150A-2V feedback carburetor, proceed as follows: a. Disconnect fuel evaporative purge return hose, if equipped, and plug connection. b. Disconnect fuel evaporative purge hose, if equipped, at air cleaner and plug nipple. 5. On all vehicles, disconnect flexible fresh air tube from air cleaner duct or adapter, then, using tool T75L-9600-A or equivalent, insert tool hose approximately 3/4 of the way into duct or fresh air tube. Secure hose with tape as necessary. 6. On vehicles equipped with thermactor systems, revise dump valve vacuum hoses as follows: a. On dump valves with two vacuum fittings, disconnect and plug hoses. b. On dump valves with one fitting or combination air bypass/air control valve, except vehicles with feedback carburetor, remove hose at dump valve and plug hose. Connect slave hose from dump valve vacuum fitting to an intake manifold vacuum fitting. c. On V8-351 engine equipped with 4180C-4V carburetor, disconnect and plug vacuum hose to dump valve. 7. On 1984 - 85 models with feedback carburetor, disconnect battery ground cable for at least 10 seconds. 8. On all models with feedback carburetor, proceed as follows: a. Disconnect electrical connector at engine coolant temperature sensor. b. Disconnect and plug hose from manifold absolute pressure (MAP) sensor. c. Disconnect and plug hose from carburetor vacuum operated throttle modulator (VOTM). d. Connect vacuum pump to manifold port of MAP sensor, evacuate to at least 20 inches Hg. and hold. e. Start engine. Leave all vacuum hoses attached to air cleaner assembly when moving assembly to perform carburetor adjustments. The air cleaner assembly must be in place when measuring engine speeds. Prolonged engine idling may cause catalyst overheating and excessive underbody temperatures. 9. On all vehicles, ensure that ignition timing is set to specifications. 10. Check engine curb idle speed or A/C-OFF RPM, adjusting as necessary. Remove PCV valve from grommet and allow PCV to draw underhood air during idle fuel mixture check. 11. With transmission in neutral, run engine at approximately 2500 RPM for 15 seconds for each mixture check. 12. With engine idling at normal operating temperature, place transmission in specified gear, gradually open propane tool valve and watch for engine speed gain, if any, on tachometer. 13. When engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. The propane cartridge must be in vertical position. If engine speed will not drop off, check propane cartridge gas supply. If necessary, repeat steps 11 through 13 with a new propane cartridge gas supply. 14. Compare measured speed gain to specified speed gain. 15. If measured speed gain is within specifications, proceed to step 20. If carburetor assembly is equipped with a tamper resistant idle adjustment feature, the carburetor must be removed from the vehicle. If idle fuel mixture adjustment is necessary, adjust mixture according to reset RPM specification. 16. If measured speed gain is zero and minimum speed gas specification is zero, proceed to step 19. 17. If measured speed gain is higher than specification, turn mixture screw(s) counterclockwise in equal amounts while simultaneously repeating steps Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments > Page 847 10 through 13 until measured speed rise meets reset RPM specification. After final adjustment, proceed to step 20. 18. If measured speed gain is lower than speed gain specifications, turn idle mixture screw(s) clockwise in equal amounts while simultaneously repeating steps 10 through 13 until measured speed rise meets reset RPM specifications. After final adjustment, proceed to step 20. 19. If there is no RPM rise and the minimum speed gain specification is zero RPM, perform speed drop test as follows. Speed drop test information is specified with the artificial enrichment requirements whenever minimum speed gain specification is zero RPM. a. While observing tachometer, adjust mixture screw(s) clockwise by number of turns specified for speed drop test, noting drop in engine speed. b. If measured speed drop is equal to or drops off by more than the speed drop specification, return mixture screw(s) to position before adjustment and proceed to step 20. c. If measured speed drop is less than specified minimum speed drop specification, leave mixture screw(s) in adjusted position and repeat steps 10 through 19. 20. Install tamper resistant feature for carburetor idle fuel air adjustment. 21. Install PCV valve in grommet. 22. On vehicles equipped with feedback carburetor, proceed as follows: a. Connect electrical connector to engine coolant temperature sensor. b. Connect hose to MAP sensor. c. Connect hose to VOTM. d. Check curb idle speed and adjust to specification. 23. Remove all test equipment, reconnect all system components and install air cleaner. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 856 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 857 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 858 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 859 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 860 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 861 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 862 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 863 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 864 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 865 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 866 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 867 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 868 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 869 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 870 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 871 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 872 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 878 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 879 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 880 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 881 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 882 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 883 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 884 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 885 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 886 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 887 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 888 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 889 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 890 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 891 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 892 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 893 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 894 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 895 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 896 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 897 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 898 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 899 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 900 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 901 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 902 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 903 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 904 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 905 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 906 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 907 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 908 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 909 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 910 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 911 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 912 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 913 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 914 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 915 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 916 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 917 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 918 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 919 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 920 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 921 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 922 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 923 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 924 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 925 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 926 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 927 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 928 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 929 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 930 FUEL INJECTED MODEL SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). Set parking brake and block wheels. - Bring engine to normal operating temperature (upper radiator hose hot). - Disconnect the electric connector on the evaporative cannister purge solenoid. - Disconnect and plug the vacuum hose to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission in "DRIVE" position. - Loosen the Throttle Solenoid Positioner (TSP) dashpot mounting bracket hold-down screw. - 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. - Retighten the TSP dashpot mounting bracket hold-down screw. - Remove the plug from the vacuum hose to the VOTM kicker and reconnect. - Reconnect the electric connector on the evaporative cannister purge solenoid. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 933 Idle Speed: Adjustments Fast Idle Speed FAST IDLE SPEED ADJUSTMENT - Place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the electric connector on the evaporative cannister purge solenoid. - Disconnect the vacuum hose at the EGR valve and plug. - Place the fast idle adjustment mechanism on specified step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove the plug from the EGR vacuum hose and reconnect. Reconnect the electric connector on the evaporative cannister purge solenoid. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: FUEL SUPPLY LINES ON EFI ENGINES WILL REMAIN PRESSURIZED FOR SOME PERIOD OF TIME AFTER THE ENGINE IS SHUT OFF. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. FUEL SYSTEM PRESSURE RELIEF - EFI ENGINES Before opening the fuel system on vehicles with EFI engines, relieve fuel pressure as follows: 1. Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch or the in-line high pressure fuel pump. 2. Crank engine for approximately ten seconds. Note: Engine may start and run for a short time. If so, crank engine an additional 5 seconds after engine stalls. 3. Re-connect the electrical connector that was disconnected in step 1 and disconnect battery ground cable. Alternative Method Some EFI vehicles have a port (fitting) on the fuel rail used for measuring fuel pressure. If so equipped, use the following method: Install fuel pressure relief tool No. T80L-9974-B or equivalent to measuring port on engine fuel rail. - Position drain hose in suitable container, then depress relief button. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications Firing Order 1-5-4-2-6-3-7-8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 942 Firing Order: Mechanical Specifications Location On Distributor FIRING ORDER: 1-5-4-2-6-3-7-8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cylinder Numbering And Distributor Location Location On Distributor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 957 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 958 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 959 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 960 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 961 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure Distributor Cap: Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 967 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 968 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure Ignition Rotor: Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 973 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 974 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 ...................................................................... ................................................................................................................. 9-20 Nm (7-15 ft-lbs) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 978 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications - Install each spark plug and tighten to 9-20 Nm (7-15 ft-lbs). Cylinder Numbering And Distributor Location Location On Distributor - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 985 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 986 Valve Clearance: Adjustments Fig. 2 Positioning crankshaft for valve clearance check Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 987 Fig. 3 Checking collapsed tappet clearance Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2, Fig. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5. b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7. 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6. 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent and check the clearance on the following valves: a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b. On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8. Valve Arrangement Front to Rear V8-302 Left Bank.................................................................................................................................. ...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank............................................. ..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank...................................................................................................................... .....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank...................................... .......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank................................................................................................................. ............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................ .............................................................................................................................................................. .I-E-I-E-I-E-I-E Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 991 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: FUEL SUPPLY LINES ON EFI ENGINES WILL REMAIN PRESSURIZED FOR SOME PERIOD OF TIME AFTER THE ENGINE IS SHUT OFF. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. FUEL SYSTEM PRESSURE RELIEF - EFI ENGINES Before opening the fuel system on vehicles with EFI engines, relieve fuel pressure as follows: 1. Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch or the in-line high pressure fuel pump. 2. Crank engine for approximately ten seconds. Note: Engine may start and run for a short time. If so, crank engine an additional 5 seconds after engine stalls. 3. Re-connect the electrical connector that was disconnected in step 1 and disconnect battery ground cable. Alternative Method Some EFI vehicles have a port (fitting) on the fuel rail used for measuring fuel pressure. If so equipped, use the following method: Install fuel pressure relief tool No. T80L-9974-B or equivalent to measuring port on engine fuel rail. - Position drain hose in suitable container, then depress relief button. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1001 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1002 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1003 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1012 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1013 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1014 Coolant: Technical Service Bulletins Engine Coolant - Recycled Coolant Not Authorized Article No. 90-4-10 COOLING SYSTEM - USE OF RECYCLED ENGINE COOLANT - SERVICE TIP FORD: 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA 1989-90 PROBE LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER MERKUR: 1985-90 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR MEDIUM/HEAVY TRUCK: 1984-90 C SERIES, F & B SERIES, L SERIES 1986-90 CARGO SERIES ISSUE: Ford Motor Company does not authorize the use of recycled engine coolant nor do they sanction the use of any machines or devices that recycle engine coolant. Recycled engine coolant is not equivalent to the factory fill OEM coolant, the Ford premium cooling system fluid (E2FZ-19549-AA) or the Ford heavy duty low silicate cooling fluid (E6HZ-19549-A). The quality of engine coolant degenerates with use. Recycling used engine coolant is very difficult to do without exposing the used coolant to additional foreign substances. Merely adding an additive to the coolant will not restore it. ACTION: Use new engine coolant that meets Ford Motor coolant specifications for the engine being serviced. Properly dispose of the used coolant. WARNING: THE DISPOSAL OF ALL USED ENGINE COOLANT MUST ALWAYS BE DONE IN ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE AND LOCAL LAWS AND REGULATIONS. PART NUMBER PART NAME CLASS E2FZ-19549-AA Coolant System Fluid - Ford V Premium E6HZ-19549-A Coolant System Fluid - Ford V Heavy Duty Low Silicate (For use in diesel powered med/hvy trucks) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4300 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Without A/C Manual Transmission, Less Super Cooling ..................................................................................................................................................... 15.0 qts Automatic Transmission, Less Super Cooling ................................................................................................................................................ 17.5 qts Models With Super Cooling ................................................................................................................. ........................................................... 18.5 qts With A/C Manual Transmission .......................................................................................................................... ............................................................ 17.5 qts Automatic Transmission ........................................... ....................................................................................................................................... 18.5 qts Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1017 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 1031 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 (V8-302 5.0L (1985)) 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 1032 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 1037 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 1047 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 (V8-302 5.0L (1985)) 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 1048 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 1053 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity Fluid - A/T: Specifications TYPE MA CAPACITY, Initial Refill*: C-6 5.0 qt (US) With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed Others 3.0 qt (US) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity > Page 1056 Fluid - A/T: Specifications Fluid Capacity Note: C6 units, 11.8 qts.; automatic overdrive units, 12 qts. Approximate. Make final check with dipstick. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 1061 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 1062 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 1063 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Page 1064 Fluid - M/T: Specifications Type 1987 5-speed Mercon(R) Automatic Transmission Fluid All others 80W EP CAPACITY, Refill: 3-speed 3.5 pt (US) 4-speed ex. OD 7.0 pt (US) W/OD 4.5 pt (US) 5-speed 7.4 pt (US) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 1069 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications TYPE: Standard 90 HP Limited-Slip 90 HP* 8.8" & 10 1/4" has removable cover, 9.0" does not CAPACITY, Refill: Front: Dana 44 3.8 pt (US) LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Label on door lock pillar shows letter and number Dana 50 4.0 pt (US) Dana 60 5.8 pt (US) Rear: Ford w/8.8" ring gear* 5.5 pt (US) 10 1/4 ring gear* 6.5 pt (US) Dana 60 & 61 6.0 pt (US) Dana 70 HD 7.4 pt (US) Dana 70 6.5 pt (US) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1072 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 1077 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 (V8-302 5.0L (1985)) 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 9.0 pt (US) Warner 1345 6.5 pt (US) Warner 1356 4.0 pt (US) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1080 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1087 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1092 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1093 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1094 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1095 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1101 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1102 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1103 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1104 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 1109 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 1110 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 1111 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Substitutes Service Tip Article No. 96-17-10 08/12/96 AIR CONDITIONING - USE OF R-12 REFRIGERANT SUBSTITUTES - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 COUGAR 1982-94 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1985-94 CARGO SERIES, F & B SERIES, L SERIES This TSB article is being republished in its entirety to list Environmental Protection Agency (EPA) reviewed NC substitutes for R-12 refrigerant. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. ACTION: If service is required, use only new or of known quality recycled refrigerant R-12. Ford Motor Company has approved R-134a as the only refrigerant substitute for R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. INFORMATION FROM THE EPA Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 1116 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 1117 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components. ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time. R-134a is approved only for systems which specify R-134a, Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes > Page 1122 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 93206 > Sep > 93 > Air Conditioning - Use of Correct Fluorescent Tracer Dye Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 9197 > May > 91 > A/C - R12 Refrigerant Service Tips Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Service Tips Article No. 91-9-7 05/01/91 AIR CONDITIONING - REFRIGERANT R-12 - SERVICE TIPS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK: 1985-90 C SERIES 1985-91 CL-CLT-9000 SERIES, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for Refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C components. ACTION: If service is required, use only NEW or RECYCLED Refrigerant R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1131 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1132 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1133 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1134 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1135 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1136 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1137 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1140 Refrigerant: Fluid Type Specifications Type ..................................................................................................................................................... ............................................... Refrigerant 12 (R-12) Ford Part Number ............................................. ........................................................................................................................................ D4AZ-19B519-A Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1145 Refrigerant Oil: Fluid Type Specifications Compressor ................................................................................................................... 500 viscosity (C9AZ-19557-B or Motorcraft VN-2 or equivalent) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Component Locations Circuit Breaker: Component Locations LH Side Of Dash Panel At Junction Block Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Component Locations > Page 1154 Circuit Breaker: Fuse and Fusible Link Locations Circuit Location Amps Power Door Locks .................Fuse Panel.....................30 Power Windows.....................In Line At Junction Block......20 Windshield Wiper..................Fuse Panel....................7.5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 1163 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 1169 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Under LH side of Instrument Panel, to right of parking brake Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 Fig. 1 Fuse Panel. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link B > Page 1181 Fusible Link: Locations Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link B > Page 1182 Fusible Link: Locations Fuse Link E At Starter Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link B > Page 1183 Fusible Link: Locations Fuse Link L Near Auxiliary Blower Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link B > Page 1184 Fusible Link: Locations Fuse Link B Attached To Auxiliary Battery Relay Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Fuse Link E At Starter Relay Fuse Link L Near Auxiliary Blower Relay Fuse Link Q At Starter Relay Fuse Link R At Starter Relay Fuse Link X At Starter Relay Fuse Links B & D Attached To Auxiliary Battery Relay Or Junction Block Fuse Links C, E, F, K, M & Q At Starter Relay Fuse Links G & H ( W/Ammeter) In Harness, RH Side Of Dash Panel Fuse Links G & R At Starter Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to proper level. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > EGR Maintenance Light > Component Information > Locations EGR Maintenance Light: Locations On Dash Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: Customer Interest Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 1201 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: All Technical Service Bulletins Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 1207 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation NOTE: This lamp is used only on models with Federal emissions systems. The lamp will be illuminated after approximately 60,000 miles of operation. The amber lens is located on the instrument panel and has the word Emissions, Emiss or EGR printed on it. On 1988 Ranger models with 2.0L/4-122 engine, the lamp lens will indicate Check Engine. After performing the required emission control maintenance, the module must be replaced or reset, depending on type of module used. On module equipped with reset feature, reset the module as follows: 1. Place ignition switch in the Off position. 2. On Aerostar models, the module is located under the instrument panel near the bulkhead connector. On Bronco and F-Series, the module is attached to the instrument cluster to the left of the steering column. On Bronco II and Ranger models, the module is located on the righthand side of the instrument panel below the glove compartment. On E Series models, the module is located under the lefthand side of the instrument panel. 3. On all models, insert a suitable phillips head screwdriver through .2 inch diameter hole located on module near the reset sticker and lightly press down and hold. 4. While still lightly pressing down on screwdriver, turn ignition switch to Run position. The emissions maintenance lamp should remain illuminated for as long as the screwdriver is pressing down. Hold screwdriver in position for approximately five seconds. 5. Remove screwdriver, lamp should go out after approximately two to five seconds, indicating the module has been reset. If lamp fails to go out, repeat reset procedure. Place ignition switch in the Off position. 6. Turn ignition switch to Run position and check to ensure emission maintenance lamp is illuminated for two to five seconds. After approximately two to five seconds the lamp should turn off. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Fig. 1 Jumper wire connections for resetting Check Engine Lamp. 1985-90 Models w/EEC-IV This lamp will be illuminated when the ignition switch is placed in the On position. After engine is started the lamp should go off, unless a problem has been detected by the EEC-IV system. After diagnosis and repair, the Check Engine/MIL lamp will automatically reset when stored codes are cleared from the EEC-IV system memory. After diagnosis and repair, EEC-IV memory may be cleared of stored codes as follows: 1. With ignition switch in the Off position, connect a jumper wire between Self Test and Self Test Input (STI) connectors, Fig. 1. On Aerostar, the Self Test and STI connectors are gray in color and are located on lefthand fender apron, near the Electronic Engine Control (EEC) relay. On Bronco and F Series, the Self Test and STI connectors are located in the area of the EEC system charcoal canister. On Bronco II and Ranger, the Self Test connector and STI connector are red in color and they are both located on the righthand fender apron near the Electronic Engine Control (EEC) relay. On E Series, the Self Test and the STI connectors are located on the righthand fender apron in the area of the MAP sensor and starter motor relay. 2. Position ignition switch in On position, then disconnect jumper wire from test connector terminals. Disconnect jumper as soon as Check Engine lamp starts flashing. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1222 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1228 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 1229 Oil Level Warning Indicator: Description and Operation This system is used to indicate a low engine oil level condition. The lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off position. The module may take a few minutes to reset. If the engine is started during this period, the last recorded reading will be displayed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH Technical Service Bulletin # 88717033088 Date: 880301 Vehicle - Body Boom Between 35 and 65 MPH VIBRATION - DRIVELINE - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE NOISE - "BODY BOOM" - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE Article No. 88-7-17 LIGHT TRUCK: 1983-87 E-150 ISSUE: "Body boom" and driveline vibration between the speeds of 35 and 65 mph (56 and 105 km/h) may be caused by one or more vehicle component areas. The vibration and boom are usually more noticeable when the AOD transmission is operating in overdrive, but may also occur when the AOD transmission is operating in third gear. In most cases there is more than one factor causing the NVH concern. ACTION: To correct this, use the following diagnostic procedures and the 1987 Light Truck Shop Manual, Section 18-01 to determine which vehicle components require attention. The diagnostic procedures should be followed in the order in which they appear in this TSB article. After the completion of each section the vehicle should be road tested to determine if the condition has been corrected. If the condition is still present, proceed to the next section. An Econoline NVH diagnostic chart is on page 52 of this TSB to assist in concern identification. Wheels & Tires, Chassis Groundout & Exhaust System Wheels and Tires 1. Make sure the front wheels are centered on the rotor hub pilot and the rear wheels are centered on the rear drum pilot by using the Rotunda Runout Gauge, 007-00014 to check wheel and tire assembly runout. NOTE: Special attention should be given to vehicles equipped with aftermarket aluminum wheels. 2. If incorrect wheel and tire assembly runout is found, loosen the lug nuts, rotate the wheel and tire assembly and carefully retighten the lug nuts finger tight. 3. Recheck the wheel and tire assembly runout while rotating the wheel and tire assembly. If the runout is okay, torque the lug nuts to 100 ft.lbs. (136 N-m). If runout is still incorrect, service as required. Body to Chassis Groundout 1. Raise the vehicle on a hoist and make sure the mounting bolts from aftermarket seats and safety belt anchors are not grounded to the frame, service as required. 2. Check to make sure the running boards are not grounded to the frame, service as required. 3. Make sure the exhaust system is not grounded to the frame, service as required. Exhaust System 1. Check to make sure an exhaust bind-up condition is not present by using the following steps: a. Road test the vehicle to determine if a "drone" noise is present each time the transmission shifts from one gear to the next between 0 and 65 MPH (0 and 105 km/h). b. If "drone" noise is present, apply the parking brake, depress the brake pedal and brake torque engine to simulate condition. The "drone" should appear around 1800 to 2000 RPM. c. Remove the exhaust system hanger in front and behind the muffler. d. Repeat Step b. If "drone" is gone, loosen the "Y" pipe at the exhaust manifold and the muffler. e. Reposition the exhaust system upward to eliminate stress on the two (2) hangers. Retighten the "Y" pipe to specification. NOTE: On 1987 vehicles, remove the front hanger bracket from the cross member. Knock out the existing retainer bolts from the hanger. Reinstall the bracket with longer bolts and add 1/4" to 1/2" stack of washers to each bolt between the bracket and cross member. This will make sure the rubber isolator is in a neutral position. Driveshaft & Road Test Procedure Information Driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1239 1. Make sure the driveshaft runout does not exceed .035". Refer to the Light Truck Shop Manual, Section 18-01-8. 2. If runout exceeds .035", install a new driveshaft. Refer to the driveshaft application chart on page 49 of this TSB for the correct service part number. 3. Make sure the drive shaft U-joints are not worn. Check for a hard to move U-joint or a U-joint that catches when moved from side to side. NOTE: If it is necessary to replace a U-joint, refer to the following "Road Test" procedure to make sure a driveshaft imbalance is not caused by the U-joint replacement. 4. If the U-joints are okay, mark the driveshaft-to-axle flange with paint to aid in re-indexing. 5. Remove the driveshaft from the axle flange and re-index 180 degrees. 6. Road test the vehicle. NOTE: If the noise and vibration are still present or not acceptable, proceed to the "Road Test" procedure below. Road Test Procedure 1. Select a road where the vehicle can be safely operated at speeds from 25 to 65 MPH (40 to 105 km/h). 2. Slowly accelerate from 25 to 65 MPH (40 to 105 km/h) and observe the speed where the noise and vibration occur. Carefully watch the 35 to 45 MPH (56 to 72 km/h) range. 3. Shift into neutral at 65 MPH (105 km/h) and coast down to 25 MPH (40 km/h) noting at what speed the noise and vibration occur. ^ If the noise and vibration were not present during coast down, the NVH concern is not with an imbalanced driveshaft. ^ Vibrations during a neutral coastdown from 65 to 45 MPH (105 to 72 km/h) indicate an imbalanced driveshaft and/or imbalanced wheel and tire assemblies. ^ Vibrations from 35 to 45 MPH (56 to 72 km/h) indicate an imbalanced driveshaft. ^ Vibration from improperly balanced wheel and tire assemblies are normally FELT in the steering wheel and seats and do not have body "boom" noise associated with it. If this is the case, balance all four (4) wheel and tire assemblies. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1240 ^ An improperly balanced driveshaft will usually have an audible noise or body "boom" noise. If this is the case, balance or replace the driveshaft. Driveshaft Balance & Rear Springs & Axle Information Driveshaft Balance 1. Raise the vehicle on a twin post hoist. 2. Start the engine, engage the transmission and run up to vibration speed. NOTE: Observe the level of vibration in the seat and steering wheel. 3. Have an assistant install one hose clamp at the rear of the driveshaft. Position the clamp with the screw head lined up with the existing balance weights on the driveshaft. 4. Start engine and run up to vibration speed. If the vibration got worse, rotate the clamp 180 degrees. Continue the procedure of rotating at 90 degree increments until all four (4) quadrants have been evaluated. Choose the best position and tighten clamp. 5. If vibration is still present, install a second clamp in the same position as the one installed in Step 4. 6. If vibration increases, scribe a line on the driveshaft at the screwhead locations. 7. Rotate one (1) clamp a 1/2" clockwise and the other 1/2" counterclockwise. Move the clamps further apart or closer together as required to "FINE TUNE" the system. Rear Springs 1. Make sure rear springs are the six leaf design. 2. If not, install two (2) new six leaf springs, (D6UZ-5560-D). Rear Axle 1. If the condition is still present after all the above sections have been completed, road test the vehicle to determine if the correct driveline angle is present or a new ring and pinion assembly is required. 2. Drive vehicle about 10-12 miles (16-19 kilometers). 3. With the transmission in overdrive for AOD transmission or in drive for C6 transmissions, accelerate to 50 MPH (80 km/h). Slowly increase the speed to 65 MPH (105 km/h) noting at what speed the noise and vibration occur. 4. Shift into neutral and coast down to 50 MPH (80 km/h). Observe whether or "boom" noise is present and at what speed. 5. If "boom" is only present in drive, measure the angle between the driveshaft and axle. If greater than 2 degrees, shim the axle at the spring seats to achieve a 1 degree angle. 6. Road test the vehicle. If the "boom" is still present, install a special "low" pitch line runout (PLRO) rear axle ring and pinion set. Refer to the following ring and pinion application chart. RING AND PINION APPLICATION CHART Axle Application Type Ratio Part Number 1983-86 9" 3.50:1 E3UZ-4209-D 1987 8.8" 3.55:1 E7TZ-4209-B NOTE: A new balanced half round circular flange, (E3UZ-4851-A) must be installed in 1983-86 units along with the 9" ring and pinion gear set. NOTE: A "boom" noise during a neutral coast indicates an imbalanced driveline. Refer back to the "Driveshaft Section" for diagnosis. PART NUMBER PART NAME CLASS E6UZ-4602-H Driveshaft C Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1241 E6UZ-4602-J Driveshaft C E6UZ-4602-K Driveshaft C E7UZ-4602-U Driveshaft C E8UZ-4602-C Driveshaft C D6UZ-5560-D Rear Spring C E3UZ-4209-D Ring and Pinion C E7TZ-4209-B Ring and Pinion B E3UZ-4851-A Flange C OTHER APPLICABLE ARTICLES: 86-15-15 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Warranty Coverages OPERATION: 880717A - Wheel and Tire Section (Includes check runout and balance all four wheels and tire assemblies) TIME: 1.6 Hrs. OPERATION: 880717B - Body to Chassis Groundout Section TIME: 0.2 Hr. OPERATION: 880717C - Exhaust System Section TIME: 0.5 Hr. OPERATION: 880717D - Driveshaft and Road Test Sections TIME: 1.1 Hrs. OPERATION: 880717F - Driveshaft Balance Section TIME: 1.4 Hrs. OPERATION: 880717G - Rear Spring Section TIME: 1.4 Hrs. - Both OPERATION: 880717H - Rear Axle Section TIME: 3.5 Hrs. - Standard Axle 4.4 Hrs. - Limited Slip Axle DLR. CODING: Basic Condition Part No.: Code: Wheel and Tire Section 1007 67 Body to Chassis Groundout Section 7000396 35 Exhaust System Section 5260 36 Driveshaft and Road Test Sections 4602 67 Driveshaft Balance Section 4602 67 Rear Spring Section 5560 53 Rear Axle Section 4209 53 NOTE: The only components that are eligible under Powertrain Coverage are part numbers 4209 and 4602. Econoline Nvh Diagnosis Chart Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1242 NOTE: If the complaint unit is a conversion van, be sure to raise vehicle on a hoist and inspect the second seat attachments to verify that the bolts are not too long and grounded to the frame cross member or other components. Also, check running board hangers to make certain that the hangers are not attached to the frame. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application Tires: All Technical Service Bulletins Tires - Best Pressure For Load Application ^33GTIRE - LOAD CAPACITY VERSUS INFLATION PRESSURE ^ TIRE - P - METRIC PASSENGER TIRES USED ON LIGHT TRUCKS ^ TIRE WEAR - EFFECTS OF INFLATION AND LOAD Article No. 89-9-16 LIGHT TRUCK: 1984-89 ALL LIGHT TRUCK LINES ISSUE: Tire wear can be affected by inflation and load. Good tread life is dependent on maintaining proper air pressure in the tires. Other factors that affect tire wear are: ^ alignment ^ speed ^ road surfaces ACTION: Keep tires inflated to the recommended pressures to obtain maximum tread life. Use the following charts and procedures to arrive at the best tire pressure for each load application. FIGURE 1 The chart in Figure 1 shows the affect of inflation and load on tire tread life. Use the chart by finding the specified inflation pressure for the vehicle as shown on the certification label and locating that pressure on the specified inflation pressure on the chart. The affects of actual air pressure and load can now be read directly off the chart. Tire load carrying capacity is a function of tire design and inflation pressures. Each tire has molded into the sidewall a maximum pressure for a specific usage. Use the following guidelines to determine load carrying capacity. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application > Page 1252 FIGURE 2 ^ For P-metric passenger tires on passenger cars, the values are as shown on the tire. ^ For P-metric passenger tires on light trucks, the load ratings are reduced to 91% to reflect the "harsher" truck environment, Figure 2. ^ For light truck style tires used on light trucks, the values are as shown for tires used in single wheel applications. ^ For light truck style tires used in dual wheel applications, the tire capacities are derated. Often, inflation pressures for specific vehicles are less than maximum capacity because the load to be carried is less than the maximum tire capacity. Inflation pressures for originally installed size tires on a vehicle are shown on the vehicle certification label along with the tire size and rated capacity for the axle system. Check the size and inflation information on the label to properly inflate the tires. Be sure that the same size tire is actually on the vehicle and then inflate it to the label's specified pressure. If other than original size tires are on the vehicle, the label's pressures are probably not correct To find proper pressures for other than original tires, use the following procedure. 1. Obtain both front and rear axle capacity ratings (GAWRR and GAWRF). 2. Divide each number by 2 to obtain the capacity at the tire. FIGURE 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application > Page 1253 3. For single wheel usage, look up the pressure in the proper chart which will meet the needed capacity, Figure 3. 4. Check the tire side wall label to see if it permits inflation to that pressure. If lower load range tires were installed (i.e., C vs. D or E), the tires may not have the needed capability. 5. Divide the value found in Step 2 by 2 again to obtain individual tire requirements for dual rear wheels. 6. Using a dual wheel inflation pressure chart, Figure 3, determine correct pressure to achieve adequate load capacities. 7. Consult the local tire outlet or the tire manufacturer's home office about tires not shown in the tables. OTHER APPLICABLE ARTICLES: 87-10-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3300 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH Technical Service Bulletin # 88717033088 Date: 880301 Vehicle - Body Boom Between 35 and 65 MPH VIBRATION - DRIVELINE - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE NOISE - "BODY BOOM" - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE Article No. 88-7-17 LIGHT TRUCK: 1983-87 E-150 ISSUE: "Body boom" and driveline vibration between the speeds of 35 and 65 mph (56 and 105 km/h) may be caused by one or more vehicle component areas. The vibration and boom are usually more noticeable when the AOD transmission is operating in overdrive, but may also occur when the AOD transmission is operating in third gear. In most cases there is more than one factor causing the NVH concern. ACTION: To correct this, use the following diagnostic procedures and the 1987 Light Truck Shop Manual, Section 18-01 to determine which vehicle components require attention. The diagnostic procedures should be followed in the order in which they appear in this TSB article. After the completion of each section the vehicle should be road tested to determine if the condition has been corrected. If the condition is still present, proceed to the next section. An Econoline NVH diagnostic chart is on page 52 of this TSB to assist in concern identification. Wheels & Tires, Chassis Groundout & Exhaust System Wheels and Tires 1. Make sure the front wheels are centered on the rotor hub pilot and the rear wheels are centered on the rear drum pilot by using the Rotunda Runout Gauge, 007-00014 to check wheel and tire assembly runout. NOTE: Special attention should be given to vehicles equipped with aftermarket aluminum wheels. 2. If incorrect wheel and tire assembly runout is found, loosen the lug nuts, rotate the wheel and tire assembly and carefully retighten the lug nuts finger tight. 3. Recheck the wheel and tire assembly runout while rotating the wheel and tire assembly. If the runout is okay, torque the lug nuts to 100 ft.lbs. (136 N-m). If runout is still incorrect, service as required. Body to Chassis Groundout 1. Raise the vehicle on a hoist and make sure the mounting bolts from aftermarket seats and safety belt anchors are not grounded to the frame, service as required. 2. Check to make sure the running boards are not grounded to the frame, service as required. 3. Make sure the exhaust system is not grounded to the frame, service as required. Exhaust System 1. Check to make sure an exhaust bind-up condition is not present by using the following steps: a. Road test the vehicle to determine if a "drone" noise is present each time the transmission shifts from one gear to the next between 0 and 65 MPH (0 and 105 km/h). b. If "drone" noise is present, apply the parking brake, depress the brake pedal and brake torque engine to simulate condition. The "drone" should appear around 1800 to 2000 RPM. c. Remove the exhaust system hanger in front and behind the muffler. d. Repeat Step b. If "drone" is gone, loosen the "Y" pipe at the exhaust manifold and the muffler. e. Reposition the exhaust system upward to eliminate stress on the two (2) hangers. Retighten the "Y" pipe to specification. NOTE: On 1987 vehicles, remove the front hanger bracket from the cross member. Knock out the existing retainer bolts from the hanger. Reinstall the bracket with longer bolts and add 1/4" to 1/2" stack of washers to each bolt between the bracket and cross member. This will make sure the rubber isolator is in a neutral position. Driveshaft & Road Test Procedure Information Driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1258 1. Make sure the driveshaft runout does not exceed .035". Refer to the Light Truck Shop Manual, Section 18-01-8. 2. If runout exceeds .035", install a new driveshaft. Refer to the driveshaft application chart on page 49 of this TSB for the correct service part number. 3. Make sure the drive shaft U-joints are not worn. Check for a hard to move U-joint or a U-joint that catches when moved from side to side. NOTE: If it is necessary to replace a U-joint, refer to the following "Road Test" procedure to make sure a driveshaft imbalance is not caused by the U-joint replacement. 4. If the U-joints are okay, mark the driveshaft-to-axle flange with paint to aid in re-indexing. 5. Remove the driveshaft from the axle flange and re-index 180 degrees. 6. Road test the vehicle. NOTE: If the noise and vibration are still present or not acceptable, proceed to the "Road Test" procedure below. Road Test Procedure 1. Select a road where the vehicle can be safely operated at speeds from 25 to 65 MPH (40 to 105 km/h). 2. Slowly accelerate from 25 to 65 MPH (40 to 105 km/h) and observe the speed where the noise and vibration occur. Carefully watch the 35 to 45 MPH (56 to 72 km/h) range. 3. Shift into neutral at 65 MPH (105 km/h) and coast down to 25 MPH (40 km/h) noting at what speed the noise and vibration occur. ^ If the noise and vibration were not present during coast down, the NVH concern is not with an imbalanced driveshaft. ^ Vibrations during a neutral coastdown from 65 to 45 MPH (105 to 72 km/h) indicate an imbalanced driveshaft and/or imbalanced wheel and tire assemblies. ^ Vibrations from 35 to 45 MPH (56 to 72 km/h) indicate an imbalanced driveshaft. ^ Vibration from improperly balanced wheel and tire assemblies are normally FELT in the steering wheel and seats and do not have body "boom" noise associated with it. If this is the case, balance all four (4) wheel and tire assemblies. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1259 ^ An improperly balanced driveshaft will usually have an audible noise or body "boom" noise. If this is the case, balance or replace the driveshaft. Driveshaft Balance & Rear Springs & Axle Information Driveshaft Balance 1. Raise the vehicle on a twin post hoist. 2. Start the engine, engage the transmission and run up to vibration speed. NOTE: Observe the level of vibration in the seat and steering wheel. 3. Have an assistant install one hose clamp at the rear of the driveshaft. Position the clamp with the screw head lined up with the existing balance weights on the driveshaft. 4. Start engine and run up to vibration speed. If the vibration got worse, rotate the clamp 180 degrees. Continue the procedure of rotating at 90 degree increments until all four (4) quadrants have been evaluated. Choose the best position and tighten clamp. 5. If vibration is still present, install a second clamp in the same position as the one installed in Step 4. 6. If vibration increases, scribe a line on the driveshaft at the screwhead locations. 7. Rotate one (1) clamp a 1/2" clockwise and the other 1/2" counterclockwise. Move the clamps further apart or closer together as required to "FINE TUNE" the system. Rear Springs 1. Make sure rear springs are the six leaf design. 2. If not, install two (2) new six leaf springs, (D6UZ-5560-D). Rear Axle 1. If the condition is still present after all the above sections have been completed, road test the vehicle to determine if the correct driveline angle is present or a new ring and pinion assembly is required. 2. Drive vehicle about 10-12 miles (16-19 kilometers). 3. With the transmission in overdrive for AOD transmission or in drive for C6 transmissions, accelerate to 50 MPH (80 km/h). Slowly increase the speed to 65 MPH (105 km/h) noting at what speed the noise and vibration occur. 4. Shift into neutral and coast down to 50 MPH (80 km/h). Observe whether or "boom" noise is present and at what speed. 5. If "boom" is only present in drive, measure the angle between the driveshaft and axle. If greater than 2 degrees, shim the axle at the spring seats to achieve a 1 degree angle. 6. Road test the vehicle. If the "boom" is still present, install a special "low" pitch line runout (PLRO) rear axle ring and pinion set. Refer to the following ring and pinion application chart. RING AND PINION APPLICATION CHART Axle Application Type Ratio Part Number 1983-86 9" 3.50:1 E3UZ-4209-D 1987 8.8" 3.55:1 E7TZ-4209-B NOTE: A new balanced half round circular flange, (E3UZ-4851-A) must be installed in 1983-86 units along with the 9" ring and pinion gear set. NOTE: A "boom" noise during a neutral coast indicates an imbalanced driveline. Refer back to the "Driveshaft Section" for diagnosis. PART NUMBER PART NAME CLASS E6UZ-4602-H Driveshaft C Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1260 E6UZ-4602-J Driveshaft C E6UZ-4602-K Driveshaft C E7UZ-4602-U Driveshaft C E8UZ-4602-C Driveshaft C D6UZ-5560-D Rear Spring C E3UZ-4209-D Ring and Pinion C E7TZ-4209-B Ring and Pinion B E3UZ-4851-A Flange C OTHER APPLICABLE ARTICLES: 86-15-15 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Warranty Coverages OPERATION: 880717A - Wheel and Tire Section (Includes check runout and balance all four wheels and tire assemblies) TIME: 1.6 Hrs. OPERATION: 880717B - Body to Chassis Groundout Section TIME: 0.2 Hr. OPERATION: 880717C - Exhaust System Section TIME: 0.5 Hr. OPERATION: 880717D - Driveshaft and Road Test Sections TIME: 1.1 Hrs. OPERATION: 880717F - Driveshaft Balance Section TIME: 1.4 Hrs. OPERATION: 880717G - Rear Spring Section TIME: 1.4 Hrs. - Both OPERATION: 880717H - Rear Axle Section TIME: 3.5 Hrs. - Standard Axle 4.4 Hrs. - Limited Slip Axle DLR. CODING: Basic Condition Part No.: Code: Wheel and Tire Section 1007 67 Body to Chassis Groundout Section 7000396 35 Exhaust System Section 5260 36 Driveshaft and Road Test Sections 4602 67 Driveshaft Balance Section 4602 67 Rear Spring Section 5560 53 Rear Axle Section 4209 53 NOTE: The only components that are eligible under Powertrain Coverage are part numbers 4209 and 4602. Econoline Nvh Diagnosis Chart Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1261 NOTE: If the complaint unit is a conversion van, be sure to raise vehicle on a hoist and inspect the second seat attachments to verify that the bolts are not too long and grounded to the frame cross member or other components. Also, check running board hangers to make certain that the hangers are not attached to the frame. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Tires: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Tires: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application Tires: All Technical Service Bulletins Tires - Best Pressure For Load Application ^33GTIRE - LOAD CAPACITY VERSUS INFLATION PRESSURE ^ TIRE - P - METRIC PASSENGER TIRES USED ON LIGHT TRUCKS ^ TIRE WEAR - EFFECTS OF INFLATION AND LOAD Article No. 89-9-16 LIGHT TRUCK: 1984-89 ALL LIGHT TRUCK LINES ISSUE: Tire wear can be affected by inflation and load. Good tread life is dependent on maintaining proper air pressure in the tires. Other factors that affect tire wear are: ^ alignment ^ speed ^ road surfaces ACTION: Keep tires inflated to the recommended pressures to obtain maximum tread life. Use the following charts and procedures to arrive at the best tire pressure for each load application. FIGURE 1 The chart in Figure 1 shows the affect of inflation and load on tire tread life. Use the chart by finding the specified inflation pressure for the vehicle as shown on the certification label and locating that pressure on the specified inflation pressure on the chart. The affects of actual air pressure and load can now be read directly off the chart. Tire load carrying capacity is a function of tire design and inflation pressures. Each tire has molded into the sidewall a maximum pressure for a specific usage. Use the following guidelines to determine load carrying capacity. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application > Page 1279 FIGURE 2 ^ For P-metric passenger tires on passenger cars, the values are as shown on the tire. ^ For P-metric passenger tires on light trucks, the load ratings are reduced to 91% to reflect the "harsher" truck environment, Figure 2. ^ For light truck style tires used on light trucks, the values are as shown for tires used in single wheel applications. ^ For light truck style tires used in dual wheel applications, the tire capacities are derated. Often, inflation pressures for specific vehicles are less than maximum capacity because the load to be carried is less than the maximum tire capacity. Inflation pressures for originally installed size tires on a vehicle are shown on the vehicle certification label along with the tire size and rated capacity for the axle system. Check the size and inflation information on the label to properly inflate the tires. Be sure that the same size tire is actually on the vehicle and then inflate it to the label's specified pressure. If other than original size tires are on the vehicle, the label's pressures are probably not correct To find proper pressures for other than original tires, use the following procedure. 1. Obtain both front and rear axle capacity ratings (GAWRR and GAWRF). 2. Divide each number by 2 to obtain the capacity at the tire. FIGURE 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application > Page 1280 3. For single wheel usage, look up the pressure in the proper chart which will meet the needed capacity, Figure 3. 4. Check the tire side wall label to see if it permits inflation to that pressure. If lower load range tires were installed (i.e., C vs. D or E), the tires may not have the needed capability. 5. Divide the value found in Step 2 by 2 again to obtain individual tire requirements for dual rear wheels. 6. Using a dual wheel inflation pressure chart, Figure 3, determine correct pressure to achieve adequate load capacities. 7. Consult the local tire outlet or the tire manufacturer's home office about tires not shown in the tables. OTHER APPLICABLE ARTICLES: 87-10-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3300 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Tires: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Tires: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes Wheels: Customer Interest Wheel - Mounting Surface Distorted Lug/Pilot Holes Article No. 91-11-16 05/30/91 ^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL WHEELS ^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL WHEELS LIGHT TRUCK: 1985-91 E-250-350, F-250-350 ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a different location. ACTION: To determine if a wheel has been damaged and should not be reused, refer to the following service procedure for details. NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL WHEEL) INSPECT FOR WHEEL DAMAGE 1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel. 2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is distorted, DO NOT reuse the wheel. 3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel. 4. Inspect the wheel mounting surface for distortion. a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which makes contact with the rear brake drum or front rotor). b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt holes and across the center of the pilot hole. c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight edge makes contact with the pilot holes, DO NOT reuse the wheel. INSTALL WHEEL 1. Inspect for lubricants on the studs and lug nuts. 2. If lubricants are present, clean throughly using naphtha or equivalent. 3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual, Section 04-04. CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE TORQUE MAY NOT PROVIDE ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION. PART NUMBER PART NAME CLASS E5TZ-1015-B Wheel AM OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911116A Wheel-Inspect 0.7 hrs 911116B Replace One Wheel And 0.4 Hr. Dynamic Balance 911116C Replace Two Wheels And 0.8 Hr. Dynamic Balance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes > Page 1297 911116D Replace Three Wheels And 1.2 Hr. Dynamic Balance 911116E Replace Four Wheels And 1.6 Hr. Dynamic Balance DEALER CODING BASIC PART NO. CONDITION CODE 1015 67 OASIS CODES: 306000, 703000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH Technical Service Bulletin # 88717033088 Date: 880301 Vehicle - Body Boom Between 35 and 65 MPH VIBRATION - DRIVELINE - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE NOISE - "BODY BOOM" - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE Article No. 88-7-17 LIGHT TRUCK: 1983-87 E-150 ISSUE: "Body boom" and driveline vibration between the speeds of 35 and 65 mph (56 and 105 km/h) may be caused by one or more vehicle component areas. The vibration and boom are usually more noticeable when the AOD transmission is operating in overdrive, but may also occur when the AOD transmission is operating in third gear. In most cases there is more than one factor causing the NVH concern. ACTION: To correct this, use the following diagnostic procedures and the 1987 Light Truck Shop Manual, Section 18-01 to determine which vehicle components require attention. The diagnostic procedures should be followed in the order in which they appear in this TSB article. After the completion of each section the vehicle should be road tested to determine if the condition has been corrected. If the condition is still present, proceed to the next section. An Econoline NVH diagnostic chart is on page 52 of this TSB to assist in concern identification. Wheels & Tires, Chassis Groundout & Exhaust System Wheels and Tires 1. Make sure the front wheels are centered on the rotor hub pilot and the rear wheels are centered on the rear drum pilot by using the Rotunda Runout Gauge, 007-00014 to check wheel and tire assembly runout. NOTE: Special attention should be given to vehicles equipped with aftermarket aluminum wheels. 2. If incorrect wheel and tire assembly runout is found, loosen the lug nuts, rotate the wheel and tire assembly and carefully retighten the lug nuts finger tight. 3. Recheck the wheel and tire assembly runout while rotating the wheel and tire assembly. If the runout is okay, torque the lug nuts to 100 ft.lbs. (136 N-m). If runout is still incorrect, service as required. Body to Chassis Groundout 1. Raise the vehicle on a hoist and make sure the mounting bolts from aftermarket seats and safety belt anchors are not grounded to the frame, service as required. 2. Check to make sure the running boards are not grounded to the frame, service as required. 3. Make sure the exhaust system is not grounded to the frame, service as required. Exhaust System 1. Check to make sure an exhaust bind-up condition is not present by using the following steps: a. Road test the vehicle to determine if a "drone" noise is present each time the transmission shifts from one gear to the next between 0 and 65 MPH (0 and 105 km/h). b. If "drone" noise is present, apply the parking brake, depress the brake pedal and brake torque engine to simulate condition. The "drone" should appear around 1800 to 2000 RPM. c. Remove the exhaust system hanger in front and behind the muffler. d. Repeat Step b. If "drone" is gone, loosen the "Y" pipe at the exhaust manifold and the muffler. e. Reposition the exhaust system upward to eliminate stress on the two (2) hangers. Retighten the "Y" pipe to specification. NOTE: On 1987 vehicles, remove the front hanger bracket from the cross member. Knock out the existing retainer bolts from the hanger. Reinstall the bracket with longer bolts and add 1/4" to 1/2" stack of washers to each bolt between the bracket and cross member. This will make sure the rubber isolator is in a neutral position. Driveshaft & Road Test Procedure Information Driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1302 1. Make sure the driveshaft runout does not exceed .035". Refer to the Light Truck Shop Manual, Section 18-01-8. 2. If runout exceeds .035", install a new driveshaft. Refer to the driveshaft application chart on page 49 of this TSB for the correct service part number. 3. Make sure the drive shaft U-joints are not worn. Check for a hard to move U-joint or a U-joint that catches when moved from side to side. NOTE: If it is necessary to replace a U-joint, refer to the following "Road Test" procedure to make sure a driveshaft imbalance is not caused by the U-joint replacement. 4. If the U-joints are okay, mark the driveshaft-to-axle flange with paint to aid in re-indexing. 5. Remove the driveshaft from the axle flange and re-index 180 degrees. 6. Road test the vehicle. NOTE: If the noise and vibration are still present or not acceptable, proceed to the "Road Test" procedure below. Road Test Procedure 1. Select a road where the vehicle can be safely operated at speeds from 25 to 65 MPH (40 to 105 km/h). 2. Slowly accelerate from 25 to 65 MPH (40 to 105 km/h) and observe the speed where the noise and vibration occur. Carefully watch the 35 to 45 MPH (56 to 72 km/h) range. 3. Shift into neutral at 65 MPH (105 km/h) and coast down to 25 MPH (40 km/h) noting at what speed the noise and vibration occur. ^ If the noise and vibration were not present during coast down, the NVH concern is not with an imbalanced driveshaft. ^ Vibrations during a neutral coastdown from 65 to 45 MPH (105 to 72 km/h) indicate an imbalanced driveshaft and/or imbalanced wheel and tire assemblies. ^ Vibrations from 35 to 45 MPH (56 to 72 km/h) indicate an imbalanced driveshaft. ^ Vibration from improperly balanced wheel and tire assemblies are normally FELT in the steering wheel and seats and do not have body "boom" noise associated with it. If this is the case, balance all four (4) wheel and tire assemblies. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1303 ^ An improperly balanced driveshaft will usually have an audible noise or body "boom" noise. If this is the case, balance or replace the driveshaft. Driveshaft Balance & Rear Springs & Axle Information Driveshaft Balance 1. Raise the vehicle on a twin post hoist. 2. Start the engine, engage the transmission and run up to vibration speed. NOTE: Observe the level of vibration in the seat and steering wheel. 3. Have an assistant install one hose clamp at the rear of the driveshaft. Position the clamp with the screw head lined up with the existing balance weights on the driveshaft. 4. Start engine and run up to vibration speed. If the vibration got worse, rotate the clamp 180 degrees. Continue the procedure of rotating at 90 degree increments until all four (4) quadrants have been evaluated. Choose the best position and tighten clamp. 5. If vibration is still present, install a second clamp in the same position as the one installed in Step 4. 6. If vibration increases, scribe a line on the driveshaft at the screwhead locations. 7. Rotate one (1) clamp a 1/2" clockwise and the other 1/2" counterclockwise. Move the clamps further apart or closer together as required to "FINE TUNE" the system. Rear Springs 1. Make sure rear springs are the six leaf design. 2. If not, install two (2) new six leaf springs, (D6UZ-5560-D). Rear Axle 1. If the condition is still present after all the above sections have been completed, road test the vehicle to determine if the correct driveline angle is present or a new ring and pinion assembly is required. 2. Drive vehicle about 10-12 miles (16-19 kilometers). 3. With the transmission in overdrive for AOD transmission or in drive for C6 transmissions, accelerate to 50 MPH (80 km/h). Slowly increase the speed to 65 MPH (105 km/h) noting at what speed the noise and vibration occur. 4. Shift into neutral and coast down to 50 MPH (80 km/h). Observe whether or "boom" noise is present and at what speed. 5. If "boom" is only present in drive, measure the angle between the driveshaft and axle. If greater than 2 degrees, shim the axle at the spring seats to achieve a 1 degree angle. 6. Road test the vehicle. If the "boom" is still present, install a special "low" pitch line runout (PLRO) rear axle ring and pinion set. Refer to the following ring and pinion application chart. RING AND PINION APPLICATION CHART Axle Application Type Ratio Part Number 1983-86 9" 3.50:1 E3UZ-4209-D 1987 8.8" 3.55:1 E7TZ-4209-B NOTE: A new balanced half round circular flange, (E3UZ-4851-A) must be installed in 1983-86 units along with the 9" ring and pinion gear set. NOTE: A "boom" noise during a neutral coast indicates an imbalanced driveline. Refer back to the "Driveshaft Section" for diagnosis. PART NUMBER PART NAME CLASS E6UZ-4602-H Driveshaft C Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1304 E6UZ-4602-J Driveshaft C E6UZ-4602-K Driveshaft C E7UZ-4602-U Driveshaft C E8UZ-4602-C Driveshaft C D6UZ-5560-D Rear Spring C E3UZ-4209-D Ring and Pinion C E7TZ-4209-B Ring and Pinion B E3UZ-4851-A Flange C OTHER APPLICABLE ARTICLES: 86-15-15 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Warranty Coverages OPERATION: 880717A - Wheel and Tire Section (Includes check runout and balance all four wheels and tire assemblies) TIME: 1.6 Hrs. OPERATION: 880717B - Body to Chassis Groundout Section TIME: 0.2 Hr. OPERATION: 880717C - Exhaust System Section TIME: 0.5 Hr. OPERATION: 880717D - Driveshaft and Road Test Sections TIME: 1.1 Hrs. OPERATION: 880717F - Driveshaft Balance Section TIME: 1.4 Hrs. OPERATION: 880717G - Rear Spring Section TIME: 1.4 Hrs. - Both OPERATION: 880717H - Rear Axle Section TIME: 3.5 Hrs. - Standard Axle 4.4 Hrs. - Limited Slip Axle DLR. CODING: Basic Condition Part No.: Code: Wheel and Tire Section 1007 67 Body to Chassis Groundout Section 7000396 35 Exhaust System Section 5260 36 Driveshaft and Road Test Sections 4602 67 Driveshaft Balance Section 4602 67 Rear Spring Section 5560 53 Rear Axle Section 4209 53 NOTE: The only components that are eligible under Powertrain Coverage are part numbers 4209 and 4602. Econoline Nvh Diagnosis Chart Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1305 NOTE: If the complaint unit is a conversion van, be sure to raise vehicle on a hoist and inspect the second seat attachments to verify that the bolts are not too long and grounded to the frame cross member or other components. Also, check running board hangers to make certain that the hangers are not attached to the frame. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes Wheels: All Technical Service Bulletins Wheel - Mounting Surface Distorted Lug/Pilot Holes Article No. 91-11-16 05/30/91 ^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL WHEELS ^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL WHEELS LIGHT TRUCK: 1985-91 E-250-350, F-250-350 ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a different location. ACTION: To determine if a wheel has been damaged and should not be reused, refer to the following service procedure for details. NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL WHEEL) INSPECT FOR WHEEL DAMAGE 1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel. 2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is distorted, DO NOT reuse the wheel. 3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel. 4. Inspect the wheel mounting surface for distortion. a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which makes contact with the rear brake drum or front rotor). b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt holes and across the center of the pilot hole. c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight edge makes contact with the pilot holes, DO NOT reuse the wheel. INSTALL WHEEL 1. Inspect for lubricants on the studs and lug nuts. 2. If lubricants are present, clean throughly using naphtha or equivalent. 3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual, Section 04-04. CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE TORQUE MAY NOT PROVIDE ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION. PART NUMBER PART NAME CLASS E5TZ-1015-B Wheel AM OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911116A Wheel-Inspect 0.7 hrs 911116B Replace One Wheel And 0.4 Hr. Dynamic Balance 911116C Replace Two Wheels And 0.8 Hr. Dynamic Balance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes > Page 1311 911116D Replace Three Wheels And 1.2 Hr. Dynamic Balance 911116E Replace Four Wheels And 1.6 Hr. Dynamic Balance DEALER CODING BASIC PART NO. CONDITION CODE 1015 67 OASIS CODES: 306000, 703000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH Technical Service Bulletin # 88717033088 Date: 880301 Vehicle - Body Boom Between 35 and 65 MPH VIBRATION - DRIVELINE - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE NOISE - "BODY BOOM" - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE Article No. 88-7-17 LIGHT TRUCK: 1983-87 E-150 ISSUE: "Body boom" and driveline vibration between the speeds of 35 and 65 mph (56 and 105 km/h) may be caused by one or more vehicle component areas. The vibration and boom are usually more noticeable when the AOD transmission is operating in overdrive, but may also occur when the AOD transmission is operating in third gear. In most cases there is more than one factor causing the NVH concern. ACTION: To correct this, use the following diagnostic procedures and the 1987 Light Truck Shop Manual, Section 18-01 to determine which vehicle components require attention. The diagnostic procedures should be followed in the order in which they appear in this TSB article. After the completion of each section the vehicle should be road tested to determine if the condition has been corrected. If the condition is still present, proceed to the next section. An Econoline NVH diagnostic chart is on page 52 of this TSB to assist in concern identification. Wheels & Tires, Chassis Groundout & Exhaust System Wheels and Tires 1. Make sure the front wheels are centered on the rotor hub pilot and the rear wheels are centered on the rear drum pilot by using the Rotunda Runout Gauge, 007-00014 to check wheel and tire assembly runout. NOTE: Special attention should be given to vehicles equipped with aftermarket aluminum wheels. 2. If incorrect wheel and tire assembly runout is found, loosen the lug nuts, rotate the wheel and tire assembly and carefully retighten the lug nuts finger tight. 3. Recheck the wheel and tire assembly runout while rotating the wheel and tire assembly. If the runout is okay, torque the lug nuts to 100 ft.lbs. (136 N-m). If runout is still incorrect, service as required. Body to Chassis Groundout 1. Raise the vehicle on a hoist and make sure the mounting bolts from aftermarket seats and safety belt anchors are not grounded to the frame, service as required. 2. Check to make sure the running boards are not grounded to the frame, service as required. 3. Make sure the exhaust system is not grounded to the frame, service as required. Exhaust System 1. Check to make sure an exhaust bind-up condition is not present by using the following steps: a. Road test the vehicle to determine if a "drone" noise is present each time the transmission shifts from one gear to the next between 0 and 65 MPH (0 and 105 km/h). b. If "drone" noise is present, apply the parking brake, depress the brake pedal and brake torque engine to simulate condition. The "drone" should appear around 1800 to 2000 RPM. c. Remove the exhaust system hanger in front and behind the muffler. d. Repeat Step b. If "drone" is gone, loosen the "Y" pipe at the exhaust manifold and the muffler. e. Reposition the exhaust system upward to eliminate stress on the two (2) hangers. Retighten the "Y" pipe to specification. NOTE: On 1987 vehicles, remove the front hanger bracket from the cross member. Knock out the existing retainer bolts from the hanger. Reinstall the bracket with longer bolts and add 1/4" to 1/2" stack of washers to each bolt between the bracket and cross member. This will make sure the rubber isolator is in a neutral position. Driveshaft & Road Test Procedure Information Driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1316 1. Make sure the driveshaft runout does not exceed .035". Refer to the Light Truck Shop Manual, Section 18-01-8. 2. If runout exceeds .035", install a new driveshaft. Refer to the driveshaft application chart on page 49 of this TSB for the correct service part number. 3. Make sure the drive shaft U-joints are not worn. Check for a hard to move U-joint or a U-joint that catches when moved from side to side. NOTE: If it is necessary to replace a U-joint, refer to the following "Road Test" procedure to make sure a driveshaft imbalance is not caused by the U-joint replacement. 4. If the U-joints are okay, mark the driveshaft-to-axle flange with paint to aid in re-indexing. 5. Remove the driveshaft from the axle flange and re-index 180 degrees. 6. Road test the vehicle. NOTE: If the noise and vibration are still present or not acceptable, proceed to the "Road Test" procedure below. Road Test Procedure 1. Select a road where the vehicle can be safely operated at speeds from 25 to 65 MPH (40 to 105 km/h). 2. Slowly accelerate from 25 to 65 MPH (40 to 105 km/h) and observe the speed where the noise and vibration occur. Carefully watch the 35 to 45 MPH (56 to 72 km/h) range. 3. Shift into neutral at 65 MPH (105 km/h) and coast down to 25 MPH (40 km/h) noting at what speed the noise and vibration occur. ^ If the noise and vibration were not present during coast down, the NVH concern is not with an imbalanced driveshaft. ^ Vibrations during a neutral coastdown from 65 to 45 MPH (105 to 72 km/h) indicate an imbalanced driveshaft and/or imbalanced wheel and tire assemblies. ^ Vibrations from 35 to 45 MPH (56 to 72 km/h) indicate an imbalanced driveshaft. ^ Vibration from improperly balanced wheel and tire assemblies are normally FELT in the steering wheel and seats and do not have body "boom" noise associated with it. If this is the case, balance all four (4) wheel and tire assemblies. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1317 ^ An improperly balanced driveshaft will usually have an audible noise or body "boom" noise. If this is the case, balance or replace the driveshaft. Driveshaft Balance & Rear Springs & Axle Information Driveshaft Balance 1. Raise the vehicle on a twin post hoist. 2. Start the engine, engage the transmission and run up to vibration speed. NOTE: Observe the level of vibration in the seat and steering wheel. 3. Have an assistant install one hose clamp at the rear of the driveshaft. Position the clamp with the screw head lined up with the existing balance weights on the driveshaft. 4. Start engine and run up to vibration speed. If the vibration got worse, rotate the clamp 180 degrees. Continue the procedure of rotating at 90 degree increments until all four (4) quadrants have been evaluated. Choose the best position and tighten clamp. 5. If vibration is still present, install a second clamp in the same position as the one installed in Step 4. 6. If vibration increases, scribe a line on the driveshaft at the screwhead locations. 7. Rotate one (1) clamp a 1/2" clockwise and the other 1/2" counterclockwise. Move the clamps further apart or closer together as required to "FINE TUNE" the system. Rear Springs 1. Make sure rear springs are the six leaf design. 2. If not, install two (2) new six leaf springs, (D6UZ-5560-D). Rear Axle 1. If the condition is still present after all the above sections have been completed, road test the vehicle to determine if the correct driveline angle is present or a new ring and pinion assembly is required. 2. Drive vehicle about 10-12 miles (16-19 kilometers). 3. With the transmission in overdrive for AOD transmission or in drive for C6 transmissions, accelerate to 50 MPH (80 km/h). Slowly increase the speed to 65 MPH (105 km/h) noting at what speed the noise and vibration occur. 4. Shift into neutral and coast down to 50 MPH (80 km/h). Observe whether or "boom" noise is present and at what speed. 5. If "boom" is only present in drive, measure the angle between the driveshaft and axle. If greater than 2 degrees, shim the axle at the spring seats to achieve a 1 degree angle. 6. Road test the vehicle. If the "boom" is still present, install a special "low" pitch line runout (PLRO) rear axle ring and pinion set. Refer to the following ring and pinion application chart. RING AND PINION APPLICATION CHART Axle Application Type Ratio Part Number 1983-86 9" 3.50:1 E3UZ-4209-D 1987 8.8" 3.55:1 E7TZ-4209-B NOTE: A new balanced half round circular flange, (E3UZ-4851-A) must be installed in 1983-86 units along with the 9" ring and pinion gear set. NOTE: A "boom" noise during a neutral coast indicates an imbalanced driveline. Refer back to the "Driveshaft Section" for diagnosis. PART NUMBER PART NAME CLASS E6UZ-4602-H Driveshaft C Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1318 E6UZ-4602-J Driveshaft C E6UZ-4602-K Driveshaft C E7UZ-4602-U Driveshaft C E8UZ-4602-C Driveshaft C D6UZ-5560-D Rear Spring C E3UZ-4209-D Ring and Pinion C E7TZ-4209-B Ring and Pinion B E3UZ-4851-A Flange C OTHER APPLICABLE ARTICLES: 86-15-15 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Warranty Coverages OPERATION: 880717A - Wheel and Tire Section (Includes check runout and balance all four wheels and tire assemblies) TIME: 1.6 Hrs. OPERATION: 880717B - Body to Chassis Groundout Section TIME: 0.2 Hr. OPERATION: 880717C - Exhaust System Section TIME: 0.5 Hr. OPERATION: 880717D - Driveshaft and Road Test Sections TIME: 1.1 Hrs. OPERATION: 880717F - Driveshaft Balance Section TIME: 1.4 Hrs. OPERATION: 880717G - Rear Spring Section TIME: 1.4 Hrs. - Both OPERATION: 880717H - Rear Axle Section TIME: 3.5 Hrs. - Standard Axle 4.4 Hrs. - Limited Slip Axle DLR. CODING: Basic Condition Part No.: Code: Wheel and Tire Section 1007 67 Body to Chassis Groundout Section 7000396 35 Exhaust System Section 5260 36 Driveshaft and Road Test Sections 4602 67 Driveshaft Balance Section 4602 67 Rear Spring Section 5560 53 Rear Axle Section 4209 53 NOTE: The only components that are eligible under Powertrain Coverage are part numbers 4209 and 4602. Econoline Nvh Diagnosis Chart Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 1319 NOTE: If the complaint unit is a conversion van, be sure to raise vehicle on a hoist and inspect the second seat attachments to verify that the bolts are not too long and grounded to the frame cross member or other components. Also, check running board hangers to make certain that the hangers are not attached to the frame. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update Wheels: All Technical Service Bulletins Wheel Attachment - Shop Manual Update Article No. 85-15-9 WHEEL ATTACHMENT - 1985 SHOP MANUAL UPDATE LIGHT TRUCK 1985 E350, F350 The following information, outlined in Section 50-2, but not shown or outlined in Section 50-11, should be added to the 1985 Light Truck Shop Manual-Section 50-11 as indicated below: Figure 3 - LIGHT TRUCK F/E/BRONCO Figure 4 - REAR WHEEL LUG NUT USAGE 1. On Page 50-11-7: Add Figure 3 of the attached sketches to Figure l0 of Page 5O-11-7 - Lug Nut Tightening Sequence. This figure shows the lug nut tightening sequence for the 5-lug and 8-lug wheels used on all light truck models and indicates the recommended lug nut tightening procedure. Figure 4 of the attached sketches shows the two wheel lug nut designs released for 1985 Light Truck vehicles. Figure 4 - REAR WHEEL LUG NUT USAGE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 1324 Figure 5 - REAR WHEEL INSTALLATION - F-350 / E-350 EQUIPPED WITH DUAL REAR WHEELS 2. On Page 50-11-7: The note concerning E350 and F350 vehicles equipped with dual rear wheels should be deleted and the following note and Figures 4 and 5 of the attached sketches be added: E350 and F350 vehicles with dual rear wheels are equipped with wheels (front/rear) which are center piloted to the hub and are attached with integral two-piece, swiveling lug nuts. The lug nut torque specification is 140 ft.lbs. +/- 15 ft.lbs. (right hand threads are used at all four wheel locations). See Figure 5 of the attached sketches for description of the wheel attachments. Figure 4 - REAR WHEEL LUG NUT USAGE WARNING: Use only integral two-piece swiveling lug nuts on 1985 vehicles equipped with dual rear wheels. Do not attempt to use cone shaped onepiece lug nuts on these vehicles. If used on wrong wheels, cone shaped one-piece lug nuts can come loose in vehicle operation. Do not attempt to use wheels which have cone shaped lug nut seats on these vehicles. Intermixing of different types of wheels can lead to damage to the wheel mounting system. Use of cone shaped one-piece nuts or intermixing of wheels could allow wheels to come off while vehicle is in motion, possibly causing loss of control and a collision. See Figure 4 of the attached sketch for lug nut description." 3. On Page 50-11-8: Delete the wheel "Torque Limits" chart and add the "Wheel Torque Limits" chart as shown. REFERENCE: For pre-delivery and wheel maintenance, refer to Pages 50-02-4, 5, 6, 7 and 51 in the 1985 Light Truck Shop Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 1325 Figure 6 - MODEL E350-F350 DUAL REAR WHEEL STUD NUTS USAGE INFORMATION For a complete description of the new and prior model dual rear wheel mounting systems for model E350 and F350 vehicles equipped with dual rear wheels, refer to the attached Figure 6. Torque Limits* Description - Model Bolt Size (Ft. Lbs.) N-m F-150, E-150, and Bronco-5-Lug Wheel 1/2-20 (85-115) 115-156 F-250 - E-350, E-250 - E-350, 8-Lug Wheel (under 8,500 GVW) 1/2-20 (85-115) 115-156 F-250 - F-350, E-250 - E-350, 8-Lug Wheel (over 8,500 GVW, Single Rear Wheel Vehicles) 9/16-18 (115-175) 156-237 F-350 - E-350, 8-Lug Wheel - Front or Rear (Dual Rear Wheel Vehicles with Integral Two-Piece Swiveling Lug Nuts) 9-16-18 (125-155) 169-210 *Torque specifications are for dirt and paint free dry bolt and nut threads. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update Wheels: All Technical Service Bulletins Wheel Attachment - Shop Manual Update Article No. 85-15-9 WHEEL ATTACHMENT - 1985 SHOP MANUAL UPDATE LIGHT TRUCK 1985 E350, F350 The following information, outlined in Section 50-2, but not shown or outlined in Section 50-11, should be added to the 1985 Light Truck Shop Manual-Section 50-11 as indicated below: Figure 3 - LIGHT TRUCK F/E/BRONCO Figure 4 - REAR WHEEL LUG NUT USAGE 1. On Page 50-11-7: Add Figure 3 of the attached sketches to Figure l0 of Page 5O-11-7 - Lug Nut Tightening Sequence. This figure shows the lug nut tightening sequence for the 5-lug and 8-lug wheels used on all light truck models and indicates the recommended lug nut tightening procedure. Figure 4 of the attached sketches shows the two wheel lug nut designs released for 1985 Light Truck vehicles. Figure 4 - REAR WHEEL LUG NUT USAGE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 1331 Figure 5 - REAR WHEEL INSTALLATION - F-350 / E-350 EQUIPPED WITH DUAL REAR WHEELS 2. On Page 50-11-7: The note concerning E350 and F350 vehicles equipped with dual rear wheels should be deleted and the following note and Figures 4 and 5 of the attached sketches be added: E350 and F350 vehicles with dual rear wheels are equipped with wheels (front/rear) which are center piloted to the hub and are attached with integral two-piece, swiveling lug nuts. The lug nut torque specification is 140 ft.lbs. +/- 15 ft.lbs. (right hand threads are used at all four wheel locations). See Figure 5 of the attached sketches for description of the wheel attachments. Figure 4 - REAR WHEEL LUG NUT USAGE WARNING: Use only integral two-piece swiveling lug nuts on 1985 vehicles equipped with dual rear wheels. Do not attempt to use cone shaped onepiece lug nuts on these vehicles. If used on wrong wheels, cone shaped one-piece lug nuts can come loose in vehicle operation. Do not attempt to use wheels which have cone shaped lug nut seats on these vehicles. Intermixing of different types of wheels can lead to damage to the wheel mounting system. Use of cone shaped one-piece nuts or intermixing of wheels could allow wheels to come off while vehicle is in motion, possibly causing loss of control and a collision. See Figure 4 of the attached sketch for lug nut description." 3. On Page 50-11-8: Delete the wheel "Torque Limits" chart and add the "Wheel Torque Limits" chart as shown. REFERENCE: For pre-delivery and wheel maintenance, refer to Pages 50-02-4, 5, 6, 7 and 51 in the 1985 Light Truck Shop Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 1332 Figure 6 - MODEL E350-F350 DUAL REAR WHEEL STUD NUTS USAGE INFORMATION For a complete description of the new and prior model dual rear wheel mounting systems for model E350 and F350 vehicles equipped with dual rear wheels, refer to the attached Figure 6. Torque Limits* Description - Model Bolt Size (Ft. Lbs.) N-m F-150, E-150, and Bronco-5-Lug Wheel 1/2-20 (85-115) 115-156 F-250 - E-350, E-250 - E-350, 8-Lug Wheel (under 8,500 GVW) 1/2-20 (85-115) 115-156 F-250 - F-350, E-250 - E-350, 8-Lug Wheel (over 8,500 GVW, Single Rear Wheel Vehicles) 9/16-18 (115-175) 156-237 F-350 - E-350, 8-Lug Wheel - Front or Rear (Dual Rear Wheel Vehicles with Integral Two-Piece Swiveling Lug Nuts) 9-16-18 (125-155) 169-210 *Torque specifications are for dirt and paint free dry bolt and nut threads. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments > Page 1336 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On Studs Wheel Fastener: Customer Interest Wheels- Lug Nuts Bind On Studs Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES 87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS LIGHT TRUCK: 1983-87 E-250/350, F-250/350 ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped in" against the stud when torqued. ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the recommended torque of 140 ft.lbs. (190 N-m). CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at intervals specified in the Owner Guide. PART NUMBER PART NAME CLASS E7TZ-1120-A Lug Nut - R.H. Thread A - Package of 4 E7TZ-1121-A Lug Nut - L.H. Thread A - Package of 4 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME: 0.5 Hr. OPERATION: 1107B - Replace wheel studs TIME: Refer to the appropriate Service Labor Time Standards Manual OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District Authorization DLR. CODING: Basic Part No. 1120 - Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1350 ^ 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1351 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On Studs Wheel Fastener: All Technical Service Bulletins Wheels- Lug Nuts Bind On Studs Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES 87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS LIGHT TRUCK: 1983-87 E-250/350, F-250/350 ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped in" against the stud when torqued. ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the recommended torque of 140 ft.lbs. (190 N-m). CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at intervals specified in the Owner Guide. PART NUMBER PART NAME CLASS E7TZ-1120-A Lug Nut - R.H. Thread A - Package of 4 E7TZ-1121-A Lug Nut - L.H. Thread A - Package of 4 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME: 0.5 Hr. OPERATION: 1107B - Replace wheel studs TIME: Refer to the appropriate Service Labor Time Standards Manual OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District Authorization DLR. CODING: Basic Part No. 1120 - Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update Wheel Fastener: All Technical Service Bulletins Wheel Attachment - Shop Manual Update Article No. 85-15-9 WHEEL ATTACHMENT - 1985 SHOP MANUAL UPDATE LIGHT TRUCK 1985 E350, F350 The following information, outlined in Section 50-2, but not shown or outlined in Section 50-11, should be added to the 1985 Light Truck Shop Manual-Section 50-11 as indicated below: Figure 3 - LIGHT TRUCK F/E/BRONCO Figure 4 - REAR WHEEL LUG NUT USAGE 1. On Page 50-11-7: Add Figure 3 of the attached sketches to Figure l0 of Page 5O-11-7 - Lug Nut Tightening Sequence. This figure shows the lug nut tightening sequence for the 5-lug and 8-lug wheels used on all light truck models and indicates the recommended lug nut tightening procedure. Figure 4 of the attached sketches shows the two wheel lug nut designs released for 1985 Light Truck vehicles. Figure 4 - REAR WHEEL LUG NUT USAGE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 1360 Figure 5 - REAR WHEEL INSTALLATION - F-350 / E-350 EQUIPPED WITH DUAL REAR WHEELS 2. On Page 50-11-7: The note concerning E350 and F350 vehicles equipped with dual rear wheels should be deleted and the following note and Figures 4 and 5 of the attached sketches be added: E350 and F350 vehicles with dual rear wheels are equipped with wheels (front/rear) which are center piloted to the hub and are attached with integral two-piece, swiveling lug nuts. The lug nut torque specification is 140 ft.lbs. +/- 15 ft.lbs. (right hand threads are used at all four wheel locations). See Figure 5 of the attached sketches for description of the wheel attachments. Figure 4 - REAR WHEEL LUG NUT USAGE WARNING: Use only integral two-piece swiveling lug nuts on 1985 vehicles equipped with dual rear wheels. Do not attempt to use cone shaped onepiece lug nuts on these vehicles. If used on wrong wheels, cone shaped one-piece lug nuts can come loose in vehicle operation. Do not attempt to use wheels which have cone shaped lug nut seats on these vehicles. Intermixing of different types of wheels can lead to damage to the wheel mounting system. Use of cone shaped one-piece nuts or intermixing of wheels could allow wheels to come off while vehicle is in motion, possibly causing loss of control and a collision. See Figure 4 of the attached sketch for lug nut description." 3. On Page 50-11-8: Delete the wheel "Torque Limits" chart and add the "Wheel Torque Limits" chart as shown. REFERENCE: For pre-delivery and wheel maintenance, refer to Pages 50-02-4, 5, 6, 7 and 51 in the 1985 Light Truck Shop Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 1361 Figure 6 - MODEL E350-F350 DUAL REAR WHEEL STUD NUTS USAGE INFORMATION For a complete description of the new and prior model dual rear wheel mounting systems for model E350 and F350 vehicles equipped with dual rear wheels, refer to the attached Figure 6. Torque Limits* Description - Model Bolt Size (Ft. Lbs.) N-m F-150, E-150, and Bronco-5-Lug Wheel 1/2-20 (85-115) 115-156 F-250 - E-350, E-250 - E-350, 8-Lug Wheel (under 8,500 GVW) 1/2-20 (85-115) 115-156 F-250 - F-350, E-250 - E-350, 8-Lug Wheel (over 8,500 GVW, Single Rear Wheel Vehicles) 9/16-18 (115-175) 156-237 F-350 - E-350, 8-Lug Wheel - Front or Rear (Dual Rear Wheel Vehicles with Integral Two-Piece Swiveling Lug Nuts) 9-16-18 (125-155) 169-210 *Torque specifications are for dirt and paint free dry bolt and nut threads. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1367 ^ 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1368 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update Wheel Fastener: All Technical Service Bulletins Wheel Attachment - Shop Manual Update Article No. 85-15-9 WHEEL ATTACHMENT - 1985 SHOP MANUAL UPDATE LIGHT TRUCK 1985 E350, F350 The following information, outlined in Section 50-2, but not shown or outlined in Section 50-11, should be added to the 1985 Light Truck Shop Manual-Section 50-11 as indicated below: Figure 3 - LIGHT TRUCK F/E/BRONCO Figure 4 - REAR WHEEL LUG NUT USAGE 1. On Page 50-11-7: Add Figure 3 of the attached sketches to Figure l0 of Page 5O-11-7 - Lug Nut Tightening Sequence. This figure shows the lug nut tightening sequence for the 5-lug and 8-lug wheels used on all light truck models and indicates the recommended lug nut tightening procedure. Figure 4 of the attached sketches shows the two wheel lug nut designs released for 1985 Light Truck vehicles. Figure 4 - REAR WHEEL LUG NUT USAGE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 1373 Figure 5 - REAR WHEEL INSTALLATION - F-350 / E-350 EQUIPPED WITH DUAL REAR WHEELS 2. On Page 50-11-7: The note concerning E350 and F350 vehicles equipped with dual rear wheels should be deleted and the following note and Figures 4 and 5 of the attached sketches be added: E350 and F350 vehicles with dual rear wheels are equipped with wheels (front/rear) which are center piloted to the hub and are attached with integral two-piece, swiveling lug nuts. The lug nut torque specification is 140 ft.lbs. +/- 15 ft.lbs. (right hand threads are used at all four wheel locations). See Figure 5 of the attached sketches for description of the wheel attachments. Figure 4 - REAR WHEEL LUG NUT USAGE WARNING: Use only integral two-piece swiveling lug nuts on 1985 vehicles equipped with dual rear wheels. Do not attempt to use cone shaped onepiece lug nuts on these vehicles. If used on wrong wheels, cone shaped one-piece lug nuts can come loose in vehicle operation. Do not attempt to use wheels which have cone shaped lug nut seats on these vehicles. Intermixing of different types of wheels can lead to damage to the wheel mounting system. Use of cone shaped one-piece nuts or intermixing of wheels could allow wheels to come off while vehicle is in motion, possibly causing loss of control and a collision. See Figure 4 of the attached sketch for lug nut description." 3. On Page 50-11-8: Delete the wheel "Torque Limits" chart and add the "Wheel Torque Limits" chart as shown. REFERENCE: For pre-delivery and wheel maintenance, refer to Pages 50-02-4, 5, 6, 7 and 51 in the 1985 Light Truck Shop Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 1374 Figure 6 - MODEL E350-F350 DUAL REAR WHEEL STUD NUTS USAGE INFORMATION For a complete description of the new and prior model dual rear wheel mounting systems for model E350 and F350 vehicles equipped with dual rear wheels, refer to the attached Figure 6. Torque Limits* Description - Model Bolt Size (Ft. Lbs.) N-m F-150, E-150, and Bronco-5-Lug Wheel 1/2-20 (85-115) 115-156 F-250 - E-350, E-250 - E-350, 8-Lug Wheel (under 8,500 GVW) 1/2-20 (85-115) 115-156 F-250 - F-350, E-250 - E-350, 8-Lug Wheel (over 8,500 GVW, Single Rear Wheel Vehicles) 9/16-18 (115-175) 156-237 F-350 - E-350, 8-Lug Wheel - Front or Rear (Dual Rear Wheel Vehicles with Integral Two-Piece Swiveling Lug Nuts) 9-16-18 (125-155) 169-210 *Torque specifications are for dirt and paint free dry bolt and nut threads. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Lug Nut Torque Patterns IMPORTANT Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for rust, damage, or dirt. Clean mating surfaces with a wire brush to remove any foreign material. Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a major cause of tire installation problems. Proper installation, including fastener torque, is essential to economical, safe and trouble free service. Use only the proper sizes and types of fasteners for safe and proper service. Tighten the fasteners a quarter turn at a time using the tightening sequence diagram as a guide. This is very important to prevent misalignment of the wheel. Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque (See WHEEL FASTENER TORQUE). CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or alignment problems. After driving the vehicle for a short distance, recheck the wheel fastener torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all fasteners to the proper torque. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1377 Wheel Fastener: Specifications Wheel Tightening Torque 1991-92 Explorer.................................................................................................................................. .................................................................100 ft/lbs 1987-92 E150....................................................................................................................................... ..................................................................100 ft/lbs 1987-92 F150....................................................................................................................................... ..................................................................100 ft/lbs 1987-92 Bronco.................................................................................................................................... ..................................................................100 ft/lbs 1987-92 Bronco II................................................................................................................................. .................................................................100 ft/lbs 1987-92 Aerostar.................................................................................................................................. ..................................................................100 ft/lbs 1987-92 Ranger.................................................................................................................................... ..................................................................100 ft/lbs 1987-92 E250....................................................................................................................................... ..................................................................140 ft/lbs 1987-92 E350....................................................................................................................................... ..................................................................140 ft/lbs 1987-92 F250....................................................................................................................................... ..................................................................140 ft/lbs 1987-92 F350....................................................................................................................................... ..................................................................140 ft/lbs 1985-86 E150....................................................................................................................................... .............................................................85-115 ft/lbs 1985-86 E200....................................................................................................................................... .............................................................85-115 ft/lbs 1985-86 F150....................................................................................................................................... .............................................................85-115 ft/lbs 1985-86 F200....................................................................................................................................... .............................................................85-115 ft/lbs 1985-86 Bronco.................................................................................................................................... ............................................................85-115 ft/lbs 1985-86 E250....................................................................................................................................... ...........................................................115-175 ft/lbs 1985-86 F250....................................................................................................................................... ...........................................................115-175 ft/lbs 1985-86 F350: Single Rear Wheels.............................................................................................................................. .......................................115-175 ft/lbs Dual Rear Wheels................................................................... ....................................................................................................125-155 ft/lbs 1983-86 Bronco.................................................................................................................................... ............................................................85-115 ft/lbs 1983-86 Bronco II................................................................................................................................. ............................................................85-115 ft/lbs 1983-86 Ranger.................................................................................................................................... .............................................................85-115 ft/lbs 1983-86 E100-250................................................................................................................................ ............................................................85-115 ft/lbs 1983-86 F100-250................................................................................................................................ .............................................................85-115 ft/lbs 1983-84 E350: Single Rear Wheels.............................................................................................................................. .......................................115-175 ft/lbs Dual Rear Wheels................................................................... ....................................................................................................175-260 ft/lbs 1983-84 F350: Single Rear Wheels.............................................................................................................................. .......................................115-175 ft/lbs Dual Rear Wheels................................................................... ....................................................................................................175-260 ft/lbs Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1387 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 1391 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1395 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Cap Bolts 19-24 ft.lb Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1400 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1401 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing: > 871112 > Jun > 87 > Engine - Knocking Noise Crankshaft Main Bearing: Customer Interest Engine - Knocking Noise Article No. ENGINE - "KNOCKING" NOISE - 5.0L 87-11-12 INCORRECT MAIN BEARING CLEARANCES FORD: 1985-86 LTD 1985-87 MUSTANG, THUNDERBIRD, FORD LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK: 1985-87 E-SERIES, F-SERIES, BRONCO This article is being republished in its entirety to advise dealership technicians that the number five (5) rear main bearing is not affected and does not require service. ISSUE: A low end "knocking" noise right after cold and/or warm engine start-up may be caused by excessive main bearing clearances in one (1) through four (4) of the five (5) main bearing journals. This condition may also be mildly present when the vehicle engine is under a no load (float) condition. The "knocking" noise can be described as sounding like a few sharp "raps". ACTION: To correct this, use the following diagnostic and service procedure to determine if oversize bearings should be installed in main bearing journals one (1) through four (4). Refer to the bearing usage chart below for service part applications. 1985-87 5.0L MAIN BEARING USAGE CHART Name Color Code Part No. Service No. Main Bearing - Blue D20E-6A338-BA C3AZ-6333-AB Lower Thrust Bearing Blue D20E-6A339-BA C3AZ-6337-AB Lower Main Bearing - Green C50E-6A338-C C3AZ-6333-AC Lower Thrust Bearing Green C50E-6A339-C C3AZ-6337-AC Lower Main Bearing - Green C50E-6333-C C3AZ-6333-S Upper Thrust Bearing Green C50E-6337-C C3AZ-6337-S Upper 1. Refer to the appropriate Shop Manual and Gasoline Engine Overhaul Manual for instruction in determining "knock" noise. 2. In addition, using an open stethoscope, search around exhaust manifold joint, thermactor system components, etc. for pulsing air or exhaust leaks that can be confused with "knocking" noise. Make sure that powertrain components and exhaust system components are not grounding out on body or chassis parts. 3. Using a contact stethoscope, locate source of "knock" (high or low, front or rear of engine, etc.). If "knock" seems to be low in engine, and is present as a few sharp "raps" right after start-up but remains under no-load or "float" conditions, main bearing clearances are likely to be the cause. 4. Remove oil pan as outlined in the appropriate Shop Manual, Section 21-21. 5. Using a "plastigage" and following procedure in appropriate Shop Manual, Section 21-01, determine main bearing clearances in journal numbers 1, 2, 3 and 4 ONLY. 6. If measured clearance is less than .002 at any journal, no action is required at journal. If measured clearance is greater than .002, but less than .003, install a "blue" half shell in main bearing cap only. Refer to bearing usage chart for correct service part number. NOTE: It is not necessary to measure clearance and/or replace the number five (5) main bearing. 7. If measured clearance is greater than .003, install a "green" half shell in main bearing cap only. Refer to bearing usage chart for correct service part number. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing: > 871112 > Jun > 87 > Engine - Knocking Noise > Page 1410 8. If, after checking bearing clearance at journals 1, 2, 3, and 4, measured clearance is still greater than .003, install a "green" half shell in upper (block) half as well as in main bearing cap. Refer to bearing usage chart for correct service part numbers. PART NUMBER PART NAME CLASS C3AZ-6333-AB Main Bearing - Lower RM C3AZ-6333-AC Main Bearing - Lower C C3AZ-6333-S Main Bearing - Upper C C3AZ-6337-AB Thrust Bearing - Lower C C3AZ-6337-AC Thrust Bearing - Lower C C3AZ-6337-S Thrust Bearing - Upper C OTHER APPLICABLE ARTICLES: Supersedes 87-6-9 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871112A TIME: 1985 1986 1987 MUSTANG/CAPRI Manual 5.0 5.2 5.2 Automatic 4.7 4.7 4.7 LTD/MARQUIS 4.7 4.7 THUNDERBIRD/COUGAR 6.4 5.6 5.6 FORD/MERCURY 4.7 5.2 5.2 LINCOLN TOWN CAR 5.6 5.2 5.2 CONTINENTAL 4.8 5.5 5.5 MARK VII 6.6 5.4 5.4 F-150/350 4x2 Manual 5.2 5.2 5.2 Automatic 5.4 5.4 5.4 4x4 Manual 5.9 5.9 5.9 Automatic 6.0 6.0 6.0 BRONCO Manual 5.9 5.9 5.9 Automatic 6.0 6.0 6.0 ECONOLINE With A/C 7.1 5.4 5.4 Without A/C 6.8 5.1 5.1 DLR. CODING: Basic Part No. 6009 - Code: 79 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing: > 871112 > Jun > 87 > Engine - Knocking Noise Crankshaft Main Bearing: All Technical Service Bulletins Engine - Knocking Noise Article No. ENGINE - "KNOCKING" NOISE - 5.0L 87-11-12 INCORRECT MAIN BEARING CLEARANCES FORD: 1985-86 LTD 1985-87 MUSTANG, THUNDERBIRD, FORD LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK: 1985-87 E-SERIES, F-SERIES, BRONCO This article is being republished in its entirety to advise dealership technicians that the number five (5) rear main bearing is not affected and does not require service. ISSUE: A low end "knocking" noise right after cold and/or warm engine start-up may be caused by excessive main bearing clearances in one (1) through four (4) of the five (5) main bearing journals. This condition may also be mildly present when the vehicle engine is under a no load (float) condition. The "knocking" noise can be described as sounding like a few sharp "raps". ACTION: To correct this, use the following diagnostic and service procedure to determine if oversize bearings should be installed in main bearing journals one (1) through four (4). Refer to the bearing usage chart below for service part applications. 1985-87 5.0L MAIN BEARING USAGE CHART Name Color Code Part No. Service No. Main Bearing - Blue D20E-6A338-BA C3AZ-6333-AB Lower Thrust Bearing Blue D20E-6A339-BA C3AZ-6337-AB Lower Main Bearing - Green C50E-6A338-C C3AZ-6333-AC Lower Thrust Bearing Green C50E-6A339-C C3AZ-6337-AC Lower Main Bearing - Green C50E-6333-C C3AZ-6333-S Upper Thrust Bearing Green C50E-6337-C C3AZ-6337-S Upper 1. Refer to the appropriate Shop Manual and Gasoline Engine Overhaul Manual for instruction in determining "knock" noise. 2. In addition, using an open stethoscope, search around exhaust manifold joint, thermactor system components, etc. for pulsing air or exhaust leaks that can be confused with "knocking" noise. Make sure that powertrain components and exhaust system components are not grounding out on body or chassis parts. 3. Using a contact stethoscope, locate source of "knock" (high or low, front or rear of engine, etc.). If "knock" seems to be low in engine, and is present as a few sharp "raps" right after start-up but remains under no-load or "float" conditions, main bearing clearances are likely to be the cause. 4. Remove oil pan as outlined in the appropriate Shop Manual, Section 21-21. 5. Using a "plastigage" and following procedure in appropriate Shop Manual, Section 21-01, determine main bearing clearances in journal numbers 1, 2, 3 and 4 ONLY. 6. If measured clearance is less than .002 at any journal, no action is required at journal. If measured clearance is greater than .002, but less than .003, install a "blue" half shell in main bearing cap only. Refer to bearing usage chart for correct service part number. NOTE: It is not necessary to measure clearance and/or replace the number five (5) main bearing. 7. If measured clearance is greater than .003, install a "green" half shell in main bearing cap only. Refer to bearing usage chart for correct service part number. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing: > 871112 > Jun > 87 > Engine - Knocking Noise > Page 1416 8. If, after checking bearing clearance at journals 1, 2, 3, and 4, measured clearance is still greater than .003, install a "green" half shell in upper (block) half as well as in main bearing cap. Refer to bearing usage chart for correct service part numbers. PART NUMBER PART NAME CLASS C3AZ-6333-AB Main Bearing - Lower RM C3AZ-6333-AC Main Bearing - Lower C C3AZ-6333-S Main Bearing - Upper C C3AZ-6337-AB Thrust Bearing - Lower C C3AZ-6337-AC Thrust Bearing - Lower C C3AZ-6337-S Thrust Bearing - Upper C OTHER APPLICABLE ARTICLES: Supersedes 87-6-9 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871112A TIME: 1985 1986 1987 MUSTANG/CAPRI Manual 5.0 5.2 5.2 Automatic 4.7 4.7 4.7 LTD/MARQUIS 4.7 4.7 THUNDERBIRD/COUGAR 6.4 5.6 5.6 FORD/MERCURY 4.7 5.2 5.2 LINCOLN TOWN CAR 5.6 5.2 5.2 CONTINENTAL 4.8 5.5 5.5 MARK VII 6.6 5.4 5.4 F-150/350 4x2 Manual 5.2 5.2 5.2 Automatic 5.4 5.4 5.4 4x4 Manual 5.9 5.9 5.9 Automatic 6.0 6.0 6.0 BRONCO Manual 5.9 5.9 5.9 Automatic 6.0 6.0 6.0 ECONOLINE With A/C 7.1 5.4 5.4 Without A/C 6.8 5.1 5.1 DLR. CODING: Basic Part No. 6009 - Code: 79 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Technical Service Bulletins > Customer Interest: > 92186 > Aug > 92 > Engine - Metal to Metal Noise Crankshaft: Customer Interest Engine - Metal to Metal Noise Article No. 92-18-6 08/26/92 ^ ENGINE - 5.0L - THRUST BEARING OR CRANKSHAFT PREMATURE WEAR - VEHICLES WITH AOD TRANSMISSION ^ NOISE - "METAL-TO-METAL" SOUND - 5.0L WITH AOD TRANSMISSION ^ TRANSMISSION - AOD - INTERFERENCE BETWEEN THE TORQUE CONVERTER AND THE FLYWHEEL BOLTS FORD: 1982-88 THUNDERBIRD 1982-90 MUSTANG 1986 LTD 1987-90 CROWN VICTORIA LINCOLN-MERCURY: 1982-87 CAPRI, CONTINENTAL 1982-88 COUGAR 1982-90 TOWN CAR 1984-90 MARK VII 1987-90 GRAND MARQUIS LIGHT TRUCK: 1982-90 BRONCO, E-150, E-250, F-150, F-250 This TSB article is being republished in its entirety to include the 1982-1987 Continental and the 1982-1990 Town Car. ISSUE: An unusual "metal-to-metal" noise from the engine may be caused by the flexing of the torque converter. The flexing condition causes an interference between the torque converter and flywheel bolts. The interference can cause the thrust bearing and the crankshaft to wear prematurely and eventually fail. ACTION: Install six (6) new flywheel bolts with reduced head height to provide additional clearance. Refer to the appropriate Shop Manual, 5.0L Engine Section, for service details. NOTE: WHEN A CRANKSHAFT IS REPLACED DUE TO THRUST BEARING FAILURE, INSTALL A NEW CRANKSHAFT THAT HAS A REVISED PILOT HOLE. THIS WILL PROVIDE ADDITIONAL CLEARANCE FOR THE TOROUE CONVERTER. USE NEW FLYWHEEL BOLTS. PART NUMBER Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Technical Service Bulletins > Customer Interest: > 92186 > Aug > 92 > Engine - Metal to Metal Noise > Page 1425 Operation Description Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92186 > Aug > 92 > Engine Metal to Metal Noise Crankshaft: All Technical Service Bulletins Engine - Metal to Metal Noise Article No. 92-18-6 08/26/92 ^ ENGINE - 5.0L - THRUST BEARING OR CRANKSHAFT PREMATURE WEAR - VEHICLES WITH AOD TRANSMISSION ^ NOISE - "METAL-TO-METAL" SOUND - 5.0L WITH AOD TRANSMISSION ^ TRANSMISSION - AOD - INTERFERENCE BETWEEN THE TORQUE CONVERTER AND THE FLYWHEEL BOLTS FORD: 1982-88 THUNDERBIRD 1982-90 MUSTANG 1986 LTD 1987-90 CROWN VICTORIA LINCOLN-MERCURY: 1982-87 CAPRI, CONTINENTAL 1982-88 COUGAR 1982-90 TOWN CAR 1984-90 MARK VII 1987-90 GRAND MARQUIS LIGHT TRUCK: 1982-90 BRONCO, E-150, E-250, F-150, F-250 This TSB article is being republished in its entirety to include the 1982-1987 Continental and the 1982-1990 Town Car. ISSUE: An unusual "metal-to-metal" noise from the engine may be caused by the flexing of the torque converter. The flexing condition causes an interference between the torque converter and flywheel bolts. The interference can cause the thrust bearing and the crankshaft to wear prematurely and eventually fail. ACTION: Install six (6) new flywheel bolts with reduced head height to provide additional clearance. Refer to the appropriate Shop Manual, 5.0L Engine Section, for service details. NOTE: WHEN A CRANKSHAFT IS REPLACED DUE TO THRUST BEARING FAILURE, INSTALL A NEW CRANKSHAFT THAT HAS A REVISED PILOT HOLE. THIS WILL PROVIDE ADDITIONAL CLEARANCE FOR THE TOROUE CONVERTER. USE NEW FLYWHEEL BOLTS. PART NUMBER Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92186 > Aug > 92 > Engine Metal to Metal Noise > Page 1431 Operation Description Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1437 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Technical Service Bulletins > All Other Service Bulletins for Crankshaft: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1443 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Technical Service Bulletins > Page 1444 Crankshaft: Specifications Main Cap Torque Main Cap Torque Main Bearing Cap Bolts 60-70 ft.lb Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter coded red 3.9984 - 3.9990 in coded blue 3.996 - 4.000 in Piston Clearance .0018-.0026 in Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1451 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1452 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 (V8-302 5.0L (1985)) 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 .0002-.0004 in Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications End Gap, Compression Ring 0.01 in End Gap, Oil Ring 0.015 in Side Clearance, Top Compression Ring 0.0013 - 0.0033 in Side Clearance, Second Compression Ring 0.002 - 0.004 in Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1463 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1464 Valve Clearance: Adjustments Fig. 2 Positioning crankshaft for valve clearance check Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 1465 Fig. 3 Checking collapsed tappet clearance Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2, Fig. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5. b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7. 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6. 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent and check the clearance on the following valves: a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b. On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8. Valve Arrangement Front to Rear V8-302 Left Bank.................................................................................................................................. ...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank............................................. ..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank...................................................................................................................... .....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank...................................... .......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank................................................................................................................. ............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................ .............................................................................................................................................................. .I-E-I-E-I-E-I-E Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: FUEL SUPPLY LINES ON EFI ENGINES WILL REMAIN PRESSURIZED FOR SOME PERIOD OF TIME AFTER THE ENGINE IS SHUT OFF. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. FUEL SYSTEM PRESSURE RELIEF - EFI ENGINES Before opening the fuel system on vehicles with EFI engines, relieve fuel pressure as follows: 1. Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch or the in-line high pressure fuel pump. 2. Crank engine for approximately ten seconds. Note: Engine may start and run for a short time. If so, crank engine an additional 5 seconds after engine stalls. 3. Re-connect the electrical connector that was disconnected in step 1 and disconnect battery ground cable. Alternative Method Some EFI vehicles have a port (fitting) on the fuel rail used for measuring fuel pressure. If so equipped, use the following method: Install fuel pressure relief tool No. T80L-9974-B or equivalent to measuring port on engine fuel rail. - Position drain hose in suitable container, then depress relief button. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1472 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Rocker Arm Cover 3-5 ft/lb ft.lb Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1479 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length Intake 2.06 in Free Length Exhaust 1.93 in Out Of Square Limit 0.078 in Installed Height Intake 1.812-1.844 in Installed Height Exhaust 1.687-1.719 in Spring Pressure, Closed, Intake 76-84 lbf at 1.72 in Spring Pressure, Closed, Exhaust 79-87 lbf at 1.68 in Spring Pressure, Open, Intake 215-237 lbf at 1.39 in Spring Pressure, Open, Exhaust 215-237 lbf at 1.39 in Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1493 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH Engine Accessory Bracket: Customer Interest Vehicle - Moaning/Droaning at 55 to 65 MPH Article No. 85-4-39 MOAN/DRONE (5.0L/5.8L) - 2100 2800 RPM LIGHT TRUCK 1983-85 ECONOLINE, F150-350, BRONCO A moan/drone condition encountered at 55-65 mph may be a 2100-2800 engine rpm-related condition. Diagnosis and servicing will require a good road test followed by servicing of: 1) engine mounting, 2) exhaust hanger, 3) alternator pulley, and 4) alternator/thermactor braces depending on vehicle model and engine combination. 1. Road Test & Service Engine Mountings a. Road test vehicle. The vehicle should be equipped with a portable tachometer and driven at a road speed of 55-65 MPH (engine speed of 2100-2800 RPM). The A/C system should be in the "off" position and the vehicle should be evaluated on a smooth surfaced road or highway. If the road test verifies a "drone/ moan" condition, then the following procedures should be followed: Figure 25 b. On Bronco and F150-350 vehicles, loosen the No. 3 crossmember/rear engine support gussets at the attachment to the crossmember. If the gussets pull away from the crossmember, add shims to the gap. Retighten mounting bolts (install larger bolts if required). Refer to attached Figure 25). c. On model F150-350 (4x2)/E150-350 vehicles, inspect rear engine insulator (mount) for correct usage of Engineering Part E3TA-6D091-A/Service Part E0TZ-6068-B (white color code). Install correct part if required. Inspect mount for correct orientation of "capture strap" which could bind up the mount. With the vehicle on a two-post hoist, neutralize the front and rear engine support insulators (front and rear engine mounts) by loosening the front and rear engine mounts attaching bolts (attaching front mounts to support bracket and the rear mount to the No. 3 crossmember. Lower the vehicle and place safety stands under the front and rear axles. Start the engine and shift the automatic transmission into "drive" and back into "neutral" several times while engine is idling. With manual transmission, load engine by shifting transmission into forward and reverse gears and, with the parking brake partially applied, slip the clutch to load the engine. Raise the vehicle and remove the axle stands. Retorque front and rear engine mount attaching bolts (refer to Section 21-21 of 1983-1984 Light Truck Shop Manual for torque specifications). Lower vehicle and remove from hoist. d. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 2. Double Link Exhaust Hanger Installation - F - 4 x 2 Models Only a. 1980-83 Vehicles Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1502 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1503 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1504 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1505 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1506 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH Engine Accessory Bracket: All Technical Service Bulletins Vehicle - Moaning/Droaning at 55 to 65 MPH Article No. 85-4-39 MOAN/DRONE (5.0L/5.8L) - 2100 2800 RPM LIGHT TRUCK 1983-85 ECONOLINE, F150-350, BRONCO A moan/drone condition encountered at 55-65 mph may be a 2100-2800 engine rpm-related condition. Diagnosis and servicing will require a good road test followed by servicing of: 1) engine mounting, 2) exhaust hanger, 3) alternator pulley, and 4) alternator/thermactor braces depending on vehicle model and engine combination. 1. Road Test & Service Engine Mountings a. Road test vehicle. The vehicle should be equipped with a portable tachometer and driven at a road speed of 55-65 MPH (engine speed of 2100-2800 RPM). The A/C system should be in the "off" position and the vehicle should be evaluated on a smooth surfaced road or highway. If the road test verifies a "drone/ moan" condition, then the following procedures should be followed: Figure 25 b. On Bronco and F150-350 vehicles, loosen the No. 3 crossmember/rear engine support gussets at the attachment to the crossmember. If the gussets pull away from the crossmember, add shims to the gap. Retighten mounting bolts (install larger bolts if required). Refer to attached Figure 25). c. On model F150-350 (4x2)/E150-350 vehicles, inspect rear engine insulator (mount) for correct usage of Engineering Part E3TA-6D091-A/Service Part E0TZ-6068-B (white color code). Install correct part if required. Inspect mount for correct orientation of "capture strap" which could bind up the mount. With the vehicle on a two-post hoist, neutralize the front and rear engine support insulators (front and rear engine mounts) by loosening the front and rear engine mounts attaching bolts (attaching front mounts to support bracket and the rear mount to the No. 3 crossmember. Lower the vehicle and place safety stands under the front and rear axles. Start the engine and shift the automatic transmission into "drive" and back into "neutral" several times while engine is idling. With manual transmission, load engine by shifting transmission into forward and reverse gears and, with the parking brake partially applied, slip the clutch to load the engine. Raise the vehicle and remove the axle stands. Retorque front and rear engine mount attaching bolts (refer to Section 21-21 of 1983-1984 Light Truck Shop Manual for torque specifications). Lower vehicle and remove from hoist. d. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 2. Double Link Exhaust Hanger Installation - F - 4 x 2 Models Only a. 1980-83 Vehicles Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1512 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1513 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1514 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1515 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Accessory Bracket: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1516 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH Engine Mount: Customer Interest Vehicle - Moaning/Droaning at 55 to 65 MPH Article No. 85-4-39 MOAN/DRONE (5.0L/5.8L) - 2100 2800 RPM LIGHT TRUCK 1983-85 ECONOLINE, F150-350, BRONCO A moan/drone condition encountered at 55-65 mph may be a 2100-2800 engine rpm-related condition. Diagnosis and servicing will require a good road test followed by servicing of: 1) engine mounting, 2) exhaust hanger, 3) alternator pulley, and 4) alternator/thermactor braces depending on vehicle model and engine combination. 1. Road Test & Service Engine Mountings a. Road test vehicle. The vehicle should be equipped with a portable tachometer and driven at a road speed of 55-65 MPH (engine speed of 2100-2800 RPM). The A/C system should be in the "off" position and the vehicle should be evaluated on a smooth surfaced road or highway. If the road test verifies a "drone/ moan" condition, then the following procedures should be followed: Figure 25 b. On Bronco and F150-350 vehicles, loosen the No. 3 crossmember/rear engine support gussets at the attachment to the crossmember. If the gussets pull away from the crossmember, add shims to the gap. Retighten mounting bolts (install larger bolts if required). Refer to attached Figure 25). c. On model F150-350 (4x2)/E150-350 vehicles, inspect rear engine insulator (mount) for correct usage of Engineering Part E3TA-6D091-A/Service Part E0TZ-6068-B (white color code). Install correct part if required. Inspect mount for correct orientation of "capture strap" which could bind up the mount. With the vehicle on a two-post hoist, neutralize the front and rear engine support insulators (front and rear engine mounts) by loosening the front and rear engine mounts attaching bolts (attaching front mounts to support bracket and the rear mount to the No. 3 crossmember. Lower the vehicle and place safety stands under the front and rear axles. Start the engine and shift the automatic transmission into "drive" and back into "neutral" several times while engine is idling. With manual transmission, load engine by shifting transmission into forward and reverse gears and, with the parking brake partially applied, slip the clutch to load the engine. Raise the vehicle and remove the axle stands. Retorque front and rear engine mount attaching bolts (refer to Section 21-21 of 1983-1984 Light Truck Shop Manual for torque specifications). Lower vehicle and remove from hoist. d. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 2. Double Link Exhaust Hanger Installation - F - 4 x 2 Models Only a. 1980-83 Vehicles Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1525 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1526 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1527 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1528 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1529 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH Engine Mount: All Technical Service Bulletins Vehicle - Moaning/Droaning at 55 to 65 MPH Article No. 85-4-39 MOAN/DRONE (5.0L/5.8L) - 2100 2800 RPM LIGHT TRUCK 1983-85 ECONOLINE, F150-350, BRONCO A moan/drone condition encountered at 55-65 mph may be a 2100-2800 engine rpm-related condition. Diagnosis and servicing will require a good road test followed by servicing of: 1) engine mounting, 2) exhaust hanger, 3) alternator pulley, and 4) alternator/thermactor braces depending on vehicle model and engine combination. 1. Road Test & Service Engine Mountings a. Road test vehicle. The vehicle should be equipped with a portable tachometer and driven at a road speed of 55-65 MPH (engine speed of 2100-2800 RPM). The A/C system should be in the "off" position and the vehicle should be evaluated on a smooth surfaced road or highway. If the road test verifies a "drone/ moan" condition, then the following procedures should be followed: Figure 25 b. On Bronco and F150-350 vehicles, loosen the No. 3 crossmember/rear engine support gussets at the attachment to the crossmember. If the gussets pull away from the crossmember, add shims to the gap. Retighten mounting bolts (install larger bolts if required). Refer to attached Figure 25). c. On model F150-350 (4x2)/E150-350 vehicles, inspect rear engine insulator (mount) for correct usage of Engineering Part E3TA-6D091-A/Service Part E0TZ-6068-B (white color code). Install correct part if required. Inspect mount for correct orientation of "capture strap" which could bind up the mount. With the vehicle on a two-post hoist, neutralize the front and rear engine support insulators (front and rear engine mounts) by loosening the front and rear engine mounts attaching bolts (attaching front mounts to support bracket and the rear mount to the No. 3 crossmember. Lower the vehicle and place safety stands under the front and rear axles. Start the engine and shift the automatic transmission into "drive" and back into "neutral" several times while engine is idling. With manual transmission, load engine by shifting transmission into forward and reverse gears and, with the parking brake partially applied, slip the clutch to load the engine. Raise the vehicle and remove the axle stands. Retorque front and rear engine mount attaching bolts (refer to Section 21-21 of 1983-1984 Light Truck Shop Manual for torque specifications). Lower vehicle and remove from hoist. d. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 2. Double Link Exhaust Hanger Installation - F - 4 x 2 Models Only a. 1980-83 Vehicles Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1535 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1536 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1537 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1538 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1539 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 1540 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. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Engine - Oil Dipstick May Not Be Read Correctly Engine Oil Dip Stick - Dip Stick Tube: Technical Service Bulletins Engine - Oil Dipstick May Not Be Read Correctly Article No. 88-8-9 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: The "markings" on the engine oil level dipstick (indicator) may not be read correctly or could possibly be misinterpreted. This can result in overfilling the engine with oil in newly delivered vehicles or thinking that the engine has been overfilled with the specified amount of oil during oil and filter changes. ACTION: If service is required, use the following guidelines to make sure of correct oil fill. NOTE: PROPER OIL FILL IS BASED ON A SPECIFIED VOLUME AND IS LISTED IN THE "VEHICLE ENGINE OIL LEVEL CAPACITY SPECIFICATION CHART" AND THE "FLUID REFILL CAPACITIES CHART" OF THE VEHICLE OWNERS GUIDE. USE THESE RECOMMENDED VOLUMES WHENEVER REFILLING THE ENGINE WITH OIL. FIGURE 6 Old Style Design Dipstick On "MAX/ADD" style dipsticks the "MAX" line represents an allowable tolerance limit of approximately 1/2 quart above the specified (normal) engine operating level, Figure 6. The oil level of a properly filled engine should indicate an oil level reading in the upper crosshatched area of the dipstick. NOTE: DO NOT "TOP OFF" TO THE "MAX" LINE. IF THE OIL LEVEL GOES ABOVE THE "MAX" LINE, A SUFFICIENT AMOUNT OF OIL SHOULD BE REMOVED TO BRING THE OIL LEVEL READING BACK INTO THE CROSSHATCHED AREA OF THE DIPSTICK. New Style Design Dipstick On "FULL/ADD", "FULL/ADD 1 QUART" or "F" style dipsticks the oil level of an engine filled with the correct amount of oil, as listed in the "Vehicle Oil Capacity Specification Chart" will normally occur slightly above the "FULL" line, Figure 6. This occurs because the "FULL" mark on the dipstick Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Engine - Oil Dipstick May Not Be Read Correctly > Page 1546 represents the lowest level of oil that could occur when an engine is filled with the specified volume of oil. This variation in oil level is due to manufacturing tolerances and oil level checking conditions. 1987-88 ENGINE OIL CAPACITY SPECIFICATION CHART Oil Fill With Filter Engine Models Change Car 1.3L All 3.9 Qts. 1.6L All 3.9 Qts. 1.9L All 4.0 Qts. 2.2L All 4.9 Qts. 2.3L OHC N.A. EFI/TC 5.0 Qts. 2.3L/2.5L HSC/PENTA 4.5 Qts. 2.9L Scorpio 5.0 Qts. 3.0L All 4.5 Qts. 3.8L All 5.0 Qts. 5.0L All 5.0 Qts. 5.8L All 5.0 Qts. Truck 2.0L Ranger 5.0 Qts. 2.3L Ranger 5.0 Qts. 2.9L Ranger 5.0 Qts. 3.0L Aerostar 4.5 Qts. 4.9L All 6.0 Qts. 5.0L All 6.0 Qts. 5.8L All 6.0 Qts. 6.1L/7.0L All 9.0 Qts. 7.5L All 6.0 Qts. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1553 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1562 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1568 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 1569 Oil Level Warning Indicator: Description and Operation This system is used to indicate a low engine oil level condition. The lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off position. The module may take a few minutes to reset. If the engine is started during this period, the last recorded reading will be displayed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 0.001-0.013 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 10.6-12.2 lbf at 1.74 in Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Removal and Installation > Page 1584 Oil Pump: Service and Repair Service Fig. 43 Oil pump. V8-255, 302, 351W 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Carbureted Intake Manifold: Specifications Lower Intake Manifold 32-33 Nm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Carbureted > Page 1589 Intake Manifold: Specifications Lower Intake Manifold 32-33 Nm Upper Intake Manifold 17-24 Nm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1590 Intake Manifold: Description and Operation The air intake manifold is a two-piece aluminum casting which provides mounting flanges for the throttle body assembly, fuel supply manifold, accelerator control brackets and the EGR valve and supply tube. Runner lengths are precisely tuned to optimize engine torque and power output. Vacuum taps in the manifold are provided to support various engine accessories. Cutouts for the fuel injectors are specially machined to prevent both air and fuel leakage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold - Carbureted Intake Manifold: Service and Repair Lower Intake Manifold - Carbureted Removal 1. Drain the cooling system. Remove the air cleaner and intake duct assembly, including the crankcase ventilation hose. 2. Disconnect the accelerator cable and speed control linkage (if so equipped) from the carburetor. Remove the accelerator cable bracket. Disconnect the automatic transmission kickdown rod at the carburetor (if so equipped). Disconnect the electric choke and carburetor solenoid wires, if so equipped. 3. Disconnect the high-tension lead and wires from the coil 4. Disconnect the spark plug wires from the spark plugs by grasping, twisting and pulling the moulded cap. Remove the wires and bracket assembly from the rocker arm cover attaching stud. Remove the distributor cap and spark plug wires as an assembly. 5. Remove the carburetor fuel inlet line. Push-connect fittings. 6. Disconnect the distributor vacuum hoses from the distributor if so equipped or Electronic Engine Control (EEC) distributor connection. Remove the distributor hold down bolt and remove the distributor. Disconnect evaporative hoses. 7. Disconnect the radiator upper hose from the coolant outlet housing, and the water temperature sending unit wire at the sending unit. Remove the heater hose from the intake manifold. 8. Loosen the clamp on the water pump by-pass hose at the coolant outlet housing and slide the hose off the outlet housing. 9. Disconnect the crankcase vent hose at the valve rocker arm cover. 10. Remove the intake manifold and carburetor as an assembly. It may be necessary to pry the intake manifold away from the cylinder heads. Remove the intake manifold gaskets and seals. Discard the intake manifold attaching bolt sealing washers. 11. If the manifold assembly is to be disassembled, identify all vacuum hoses before disconnecting them. Remove the coolant outlet housing gasket and thermostat. Remove the ignition coil, temperature sending unit, carburetor, spacer, (on EEC engines remove Exhaust Gas Recirculation (EGR) cooler and related parts) gasket, vacuum fitting, accelerator retracting spring bracket and choke cable bracket. Installation 1. If the intake manifold assembly was disassembled, install the temperature sending unit (threads coated with electrical conductive sealer), ignition coil, carburetor, spacer, (on EEC engine install EGR cooler and related parts) gaskets, vacuum fitting, accelerator retracting spring bracket and choke cable bracket. Position the thermostat in the coolant outlet housing. Coat the new thermostat gasket with water-resistant sealer such as Ford Perfect Seal or equivalent, and position it on the coolant outlet housing. Install the coolant outlet housing. Tighten to 13-16 N-m (9-12 ft-lbs). Connect all vacuum hoses. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold - Carbureted > Page 1593 2. Clean the mating surfaces of the intake manifold, cylinder heads and cylinder block using a solvent such as Ford Spot Remover or equivalent. Apply a 3.2 mm (1/8 inch) bead of RTV sealer, at the points shown. 3. Apply a 1.6 mm (1/16 inch) bead of RTV sealer to the outer end of each intake manifold seal for the full width of the seal (4 places). NOTE: This sealer sets-up in 15 minutes, so it is important that assembly be completed promptly. Do not drip any sealer into the engine valley. Position the seals on the cylinder block and new gaskets on the cylinder heads with trademark towards cylinder head with the gaskets interlocked with the seal tabs. Be sure the holes in the gaskets are aligned with the holes in the cylinder heads. 4. Carefully lower the intake manifold into position on the cylinder block and cylinder heads. NOTE: After the intake manifold is in place, run a finger around the seal area to make sure the seals are in place. If the seals are not in place, remove the intake manifold and position the seals. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold - Carbureted > Page 1594 5. Be sure the holes in the manifold gaskets and manifold are in alignment. Install the intake manifold attaching nuts and bolts. Tighten all nuts and bolts in sequence to 32-33 N-m (23-25 ft-lbs). NOTE: After completing the remaining assembly steps, operate the engine until it reaches normal operating temperature, then re-tighten the manifold nuts and bolts in sequence to 32-33 N-m (23-25 ft-lbs). 6. Install the water pump by-pass hose on the coolant outlet housing. Slide the clamp into position and tighten the clamp. 7. Connect the radiator upper hose. Install the heater hose and connect the hose to the intake manifold. 8. Install the fuel inlet line. 9. ROTATE the crankshaft damper until the No.1 piston is on Top Dead Center (TDC) at the end of the compression stroke. Install the distributor. 10. Install the distributor cap. Connect the spark plug wires and bracket assembly to attaching stud on rocker arm cover and connect the wires to the plugs. 11. Connect crankcase vent hose. Connect the high-tension lead and coil wires. 12. Connect accelerator cable and accelerator cable bracket. Connect speed control cable, if so equipped. Connect the choke cable. Connect electric choke and carburetor wires, if so equipped. Connect the automatic transmission kickdown rod/cable at the carburetor (if so equipped). Reconnect evaporative canister hoses. 13. Fill and bleed the cooling system. WARNING: DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN HAS BEEN FIRST EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. 14. Start the engine and check and adjust the ignition timing. Connect the distributor vacuum hoses to the distributor, if so equipped. 15. Operate the engine at fast idle and check all hose connections and gaskets for leaks. Operate the engine until engine temperatures have stabilized and adjust the engine idle speed and idle fuel mixture to specifications on engine decal. Re-tighten the intake manifold bolts in sequence to 32-33 N-m (23-25 ft-lbs). 16. Adjust the transmission throttle linkage. Install the air cleaner and intake duct assembly, including the closed crankcase ventilation hose. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold - Carbureted > Page 1595 Intake Manifold: Service and Repair Fuel Injected Upper Intake Manifold Pre-Service Procedures The fuel charging assembly consists of the air throttle body, and the upper and lower intake manifolds. Prior to service or removal of the fuel charging assembly, the following steps must be taken: 1. Open hood and install protective covers. 2. Disconnect negative battery lead and secure it out of the way. 3. Remove fuel cap at tank pressure. 4. Release pressure from fuel system. Removal 1. Disconnect electrical connectors at air bypass valve, Throttle Position Sensor (TPS) and Exhaust Gas Recirculation (EGR) Position Sensor. 2. Disconnect throttle linkage at throttle ball and Automatic Overdrive (AOD) transmission linkage from throttle body. Remove two bolts securing bracket to intake and position bracket with cables out of way. 3. Disconnect upper intake manifold vacuum fitting connections by disconnecting all vacuum lines to vacuum tree, vacuum lines to EGR valve, and vacuum line to fuel pressure regulator. 4. Disconnect Positive Crankcase Ventilation (PCV) system by disconnecting hose from fitting on rear of upper manifold. 5. Remove two canister purge lines from fittings on throttle body. 6. Disconnect EGR tube from EGR valve by removing flange nut. 7. Remove bolt from upper intake support bracket to upper manifold. 8. Remove six upper intake manifold retaining bolts. 9. Remove upper intake and throttle body as an assembly from lower intake manifold. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold - Carbureted > Page 1596 Installation 1. Clean and inspect the mounting faces of the tower and upper intake manifolds. 2. Position new gasket on lower intake mounting face. The use of alignment studs may be helpful. 3. Install upper intake manifold and throttle body assembly to lower manifold making sure gasket remains in place (if alignment studs aren't used). 4. Install six upper intake manifold retaining bolts and tighten to 17-24 N-m (12-18 ft-lbs). 5. Install upper intake support bracket-to-upper manifold attaching bolt. 6. Install EGR tube. 7. Install canister purge lines to fittings on throttle body. 8. Connect PCV hose to rear of upper manifold. 9. Connect vacuum lines to vacuum tree, EGR valve, and fuel pressure regulator. 10. Position throttle linkage bracket with cables to upper intake manifold. Install two attaching bolts and tighten to specification. Connect throttle cable and AOD transmission cable to throttle body. 11. Connect electrical connectors at air bypass valve, TPS, and EGR position sensor. NOTE: If lower intake manifold was removed, fill and bleed cooling system. Post-Service Procedures After the service is complete and the fuel charging assembly is installed to engine, the following steps must be taken: 1. Install fuel cap at tank. 2. Connect negative battery lead. 3. Turn Key ON/OFF several times without starting engine to, check for fuel leaks. NOTE: Check all connections at fuel rails, push connect fittings, etc. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold - Carbureted > Page 1597 CAUTION: The fuel system is normally pressurized to 276 kPa (40 psi). 4. Start engine and warm to operating temperature. Check for coolant leak if coolant was removed. 5. Perform Electronic Engine Control (EEC-IV) Self Test to check systems function. Lower Intake Manifold Pre-Service Procedures The fuel charging assembly consists of the air throttle body, and the upper and lower intake manifolds. Prior to service or removal of the fuel charging assembly, the following steps must be taken: 1. Open hood and install protective covers. 2. Disconnect negative battery lead and secure it out of the way. 3. Remove fuel cap at tank pressure. 4. Release pressure from fuel system. Removal 1. Remove intake manifold/throttle body assembly and air cleaner assembly must be removed prior to lower intake manifold removal. 2. Drain the coolant system. 3. Remove distributor assembly, cap and wires. Mark position of distributor and rotor during removal so that they can be installed in their original position. 4. Disconnect the electrical connections at the Engine Coolant Temperature (ECT) Sensor, Engine Temperature Sending Unit, Air Charge Temperature (ACT) Sensor, and Knock Sensor (KS). 5. Disconnect the injector wiring harness from main harness assembly. 6. Remove Exhaust Gas Oxygen (EGO) sensor ground wire from intake manifold stud. NOTE: The plated stud and ground wire must be Installed in the same position as which it was removed. 7. Disconnect fuel supply and return lines from fuel rails. 8. Remove upper radiator hose from thermostat housing. 9. Remove water bypass hose. 10. Remove heater outlet hose at intake manifold. 11. Remove air cleaner bracket by removing three attaching nuts. (Two nuts on intake manifold and one nut on exhaust manifold.) 12. Remove nut securing coil bracket and move bracket out of way. 13. Remove intake attaching bolts and studs, noting location of studs and bolts. 14. Remove lower intake manifold assembly. Installation 1. Clean and inspect the mounting faces of the lower intake cylinder heads and cylinder block surfaces. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold - Carbureted > Page 1598 2. Apply 1/16 inch bead of RTV sealer to the end seals (junction). 3. Install end seals on the cylinder block and new gaskets on the cylinder heads. NOTE: The gaskets must be interlocked with the seal tabs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold - Carbureted > Page 1599 4. Install two locator pins into opposite corners. 5. Carefully lower intake manifold assembly into position. 6. Install intake manifold bolts and studs. Tighten all bolts and studs in sequence to 32-33 N-m (23-25 ft-lbs). Wait ten minutes, then tighten all bolts and studs in sequence again to specification. 7. Position coil bracket and hold in place while tightening nut. 8. Install air cleaner bracket to intake manifold studs and exhaust manifold stud. Install attaching nuts and tighten to 19-21 N-m (8-10 ft-lbs). 9. Install upper radiator hose and water bypass hose to thermostat housing. 10. Install heater outlet hose to intake manifold. 11. Connect fuel supply and return lines to fuel rails. 12. Connect the electrical connectors to ECT sensor, ACT sensor, Engine Temperature Sender, and KS. 13. Install distributor assembly in the proper position as noted during removal. Install distributor cap and wires. Check and adjust ignition timing per specification on the engine decal. 14. Install upper intake manifold. Post-Service Procedures After the service is complete and the fuel charging assembly is installed to engine, the following steps must be taken: 1. Install fuel cap at tank. 2. Connect negative battery lead. 3. Turn Key ON/OFF several times without starting engine to, check for fuel leaks. NOTE: Check all connections at fuel rails, push connect fittings, etc. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold - Carbureted > Page 1600 CAUTION: The fuel system is normally pressurized to 276 kPa (40 psi). 4. Start engine and warm to operating temperature. Check for coolant leak if coolant was removed. 5. Perform Electronic Engine Control (EEC-IV) Self Test to check systems function. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1610 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1616 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 1617 Oil Level Warning Indicator: Description and Operation This system is used to indicate a low engine oil level condition. The lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off position. The module may take a few minutes to reset. If the engine is started during this period, the last recorded reading will be displayed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Crankshaft Seal - Leaks, Air Pressure Test Crankshaft Main Bearing Seal: Technical Service Bulletins Crankshaft Seal - Leaks, Air Pressure Test Article No. 86-3-14 LEAK OIL - CRANKSHAFT SEAL - AIR PRESSURE TEST FORD 1986 and Prior FORD, THUNDERBIRD, LTD, ESCORT, FAIRMONT, MUSTANG, EXP, TAURUS LINCOLN-MERCURY 1986 and Prior LINCOLN, MARK, CONTINENTAL, MERCURY, MARQUIS, COUGAR, CAPRI, LYNX, LN7, SABLE LIGHT TRUCK 1986 and Prior RANGER, BRONCO II, AEROSTAR, E AND F SERIES To prevent repeat servicing on engines suspected of oil leakage at the crankshaft seal, determine if the leak is actually from the seal or from another source such as the rear pan seal or galley plugs. The one-piece rear crankshaft seal is released for all passenger car and light truck engines and has proven to be more reliable than the rope or split lip design formerly used. Performing the oil leak air pressure check outlined in all Car and Truck Powertrain Shop Manuals, Section 21- 01 will accurately identify the location of the leak and can verify correction after servicing before the transmission is reinstalled. OTHER APPLICABLE ARTICLES: 80-15-5, 83-14-8 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 1629 Crankshaft Main Bearing Seal: Specifications Main Bearing Cap Bolt Torque ....................................................................................................................................................... 82-94 Nm (60-70 ft-lbs) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal Crankshaft Main Bearing Seal: Service and Repair Removal NOTE: If crankshaft rear oil seal replacement is the only operation being performed, it can be done in the vehicle. If the oil seal is being replaced in conjunction with a rear main bearing replacement, the engine must be removed from the vehicle. To replace the seal only, proceed as follows: 1. Disconnect battery ground cable from battery, then remove the starter motor. 2. Disconnect the transmission from the engine and slide it back. 3. On a manual shift transmission, remove the pressure plate and cover assembly and the clutch disc. 4. Remove flywheel attaching bolts and remove the flywheel and engine rear cover plate. CAUTION: Avoid scratching or damaging the oil seal surface. 5. Use an awl to punch one hole into the seal metal surface between the seal lip and block. Screw the threaded end of a Jet Plug Remover or equivalent into the hole, and remove the seal. 6. Clean the oil seal recess in the cylinder block and main bearing cap. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal > Page 1632 Crankshaft Main Bearing Seal: Service and Repair Installation 1. Clean, inspect, and polish the rear oil seal rubbing surface on the crankshaft. 2. Coat new oil seal and crankshaft with a light film of engine oil. Crankshaft Rear Oil Seal. CAUTION: Do not apply grease on seal for lubrication. 3. Start the seal into the recess with the seal lip facing FORWARD and install it with a rear oil seal replacer tool. Keep the tool straight with the centerline of the crankshaft and install the seal until the tool contacts the cylinder block surface. Remove the tool and inspect the seal to ensure it was not damaged during installation. 4. Install the engine rear cover plate. Position the flywheel on the crankshaft flange. Coat the threads of the flywheel attaching bolts with Pipe Sealant with TEFLON(R) or equivalent, and install the bolts. Tighten the bolts in sequence across from each other to 102-115 Nm (75-85 ft-lbs). 5. On a manual shift transmission, install the clutch disc and the pressure plate assembly. 6. Install the transmission. On an automatic transmission, do not adjust the transmission linkage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1633 Crankshaft Main Bearing Seal: Tools and Equipment Special Service Tool(s) Required: Rear Oil Seal Replacer Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Front Crankshaft Seal - Design Change Front Crankshaft Seal: Technical Service Bulletins Front Crankshaft Seal - Design Change Article No. 85-15-10 DESIGN CHANGE - FRONT CRANKSHAFT 5.0L SEAL (4.9L) LIGHT TRUCK 1985 E, F, BRONCO Engines built from 5-16-85 have a new design front cover and crankshaft seal. The new seal is a front entry, dual lip design. This is to improve oil control and allow replacement without removing the front cover. The 4.9L seal is the same as the 5.0L seal so the procedure found in the 1985 Truck Shop Manual, Volume B, Section 21-21-25 (for 5.0L) should be used when replacing the seal. The 1986 Shop Manual will reflect the proper procedure in the 4.9L engine section. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Carburetor Fuel Pressure: Specifications Carburetor 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Carburetor > Page 1650 Fuel Pressure: Specifications Fuel Injection FUEL SYSTEM SPECIFICATIONS Pressure Key On Engine Off ............................................................................................................................... ................................................... 35-45 psi Engine Idling .................................................................... ....................................................................................................................... 28-38 psi Volume A minimum of 170 ml (5.6 oz) in 10 seconds. WARNING: Fuel supply lines will remain pressurized for some period of time after the engine is shut off. Before opening the fuel system, relieve the fuel pressure. FUEL PRESSURE RELIEF PROCEDURE - Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch, or the in-line high pressure fuel pump. - Crank engine for about ten seconds. NOTE: Engine may start and run for a short time. If so, crank engine an additional five seconds after engine stalls. - Reconnect the electrical connector that was disconnected in the first step. - Disconnect negative battery cable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1651 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments Fig. 1 Propane enrichment specifications Refer to Propane Enrichment Chart, Fig. 1, when adjusting. 1. Apply parking brake, block wheels, disconnect automatic brake release, if equipped, and plug vacuum connection. 2. Connect suitable tachometer to engine. 3. If vehicle is equipped with hot idle compensator (HIC), ensure HIC is in closed position and remains closed throughout test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to ensure HIC is closed. 4. On 1983 models except V8-302 engine with 2150A-2V feedback carburetor, proceed as follows: a. Disconnect fuel evaporative purge return hose, if equipped, and plug connection. b. Disconnect fuel evaporative purge hose, if equipped, at air cleaner and plug nipple. 5. On all vehicles, disconnect flexible fresh air tube from air cleaner duct or adapter, then, using tool T75L-9600-A or equivalent, insert tool hose approximately 3/4 of the way into duct or fresh air tube. Secure hose with tape as necessary. 6. On vehicles equipped with thermactor systems, revise dump valve vacuum hoses as follows: a. On dump valves with two vacuum fittings, disconnect and plug hoses. b. On dump valves with one fitting or combination air bypass/air control valve, except vehicles with feedback carburetor, remove hose at dump valve and plug hose. Connect slave hose from dump valve vacuum fitting to an intake manifold vacuum fitting. c. On V8-351 engine equipped with 4180C-4V carburetor, disconnect and plug vacuum hose to dump valve. 7. On 1984 - 85 models with feedback carburetor, disconnect battery ground cable for at least 10 seconds. 8. On all models with feedback carburetor, proceed as follows: a. Disconnect electrical connector at engine coolant temperature sensor. b. Disconnect and plug hose from manifold absolute pressure (MAP) sensor. c. Disconnect and plug hose from carburetor vacuum operated throttle modulator (VOTM). d. Connect vacuum pump to manifold port of MAP sensor, evacuate to at least 20 inches Hg. and hold. e. Start engine. Leave all vacuum hoses attached to air cleaner assembly when moving assembly to perform carburetor adjustments. The air cleaner assembly must be in place when measuring engine speeds. Prolonged engine idling may cause catalyst overheating and excessive underbody temperatures. 9. On all vehicles, ensure that ignition timing is set to specifications. 10. Check engine curb idle speed or A/C-OFF RPM, adjusting as necessary. Remove PCV valve from grommet and allow PCV to draw underhood air during idle fuel mixture check. 11. With transmission in neutral, run engine at approximately 2500 RPM for 15 seconds for each mixture check. 12. With engine idling at normal operating temperature, place transmission in specified gear, gradually open propane tool valve and watch for engine speed gain, if any, on tachometer. 13. When engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. The propane cartridge must be in vertical position. If engine speed will not drop off, check propane cartridge gas supply. If necessary, repeat steps 11 through 13 with a new propane cartridge gas supply. 14. Compare measured speed gain to specified speed gain. 15. If measured speed gain is within specifications, proceed to step 20. If carburetor assembly is equipped with a tamper resistant idle adjustment feature, the carburetor must be removed from the vehicle. If idle fuel mixture adjustment is necessary, adjust mixture according to reset RPM specification. 16. If measured speed gain is zero and minimum speed gas specification is zero, proceed to step 19. 17. If measured speed gain is higher than specification, turn mixture screw(s) counterclockwise in equal amounts while simultaneously repeating steps Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments > Page 1655 10 through 13 until measured speed rise meets reset RPM specification. After final adjustment, proceed to step 20. 18. If measured speed gain is lower than speed gain specifications, turn idle mixture screw(s) clockwise in equal amounts while simultaneously repeating steps 10 through 13 until measured speed rise meets reset RPM specifications. After final adjustment, proceed to step 20. 19. If there is no RPM rise and the minimum speed gain specification is zero RPM, perform speed drop test as follows. Speed drop test information is specified with the artificial enrichment requirements whenever minimum speed gain specification is zero RPM. a. While observing tachometer, adjust mixture screw(s) clockwise by number of turns specified for speed drop test, noting drop in engine speed. b. If measured speed drop is equal to or drops off by more than the speed drop specification, return mixture screw(s) to position before adjustment and proceed to step 20. c. If measured speed drop is less than specified minimum speed drop specification, leave mixture screw(s) in adjusted position and repeat steps 10 through 19. 20. Install tamper resistant feature for carburetor idle fuel air adjustment. 21. Install PCV valve in grommet. 22. On vehicles equipped with feedback carburetor, proceed as follows: a. Connect electrical connector to engine coolant temperature sensor. b. Connect hose to MAP sensor. c. Connect hose to VOTM. d. Check curb idle speed and adjust to specification. 23. Remove all test equipment, reconnect all system components and install air cleaner. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1664 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1665 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1666 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1667 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1668 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1669 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1670 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1671 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1672 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1673 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1674 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1675 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1676 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1677 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1678 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1679 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1680 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1686 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1687 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1688 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1689 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1690 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1691 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1692 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1693 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1694 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1695 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1696 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1697 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1698 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1699 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1700 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1701 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1702 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1703 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1704 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1705 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1706 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1707 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1708 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1709 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1710 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1711 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1712 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1713 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1714 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1715 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1716 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1717 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1718 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1719 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1720 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1721 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1722 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1723 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1724 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1725 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1726 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1727 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1728 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1729 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1730 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1731 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1732 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1733 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1734 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1735 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1736 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1737 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1738 FUEL INJECTED MODEL SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). Set parking brake and block wheels. - Bring engine to normal operating temperature (upper radiator hose hot). - Disconnect the electric connector on the evaporative cannister purge solenoid. - Disconnect and plug the vacuum hose to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission in "DRIVE" position. - Loosen the Throttle Solenoid Positioner (TSP) dashpot mounting bracket hold-down screw. - 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. - Retighten the TSP dashpot mounting bracket hold-down screw. - Remove the plug from the vacuum hose to the VOTM kicker and reconnect. - Reconnect the electric connector on the evaporative cannister purge solenoid. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1741 Idle Speed: Adjustments Fast Idle Speed FAST IDLE SPEED ADJUSTMENT - Place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the electric connector on the evaporative cannister purge solenoid. - Disconnect the vacuum hose at the EGR valve and plug. - Place the fast idle adjustment mechanism on specified step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove the plug from the EGR vacuum hose and reconnect. Reconnect the electric connector on the evaporative cannister purge solenoid. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: FUEL SUPPLY LINES ON EFI ENGINES WILL REMAIN PRESSURIZED FOR SOME PERIOD OF TIME AFTER THE ENGINE IS SHUT OFF. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. FUEL SYSTEM PRESSURE RELIEF - EFI ENGINES Before opening the fuel system on vehicles with EFI engines, relieve fuel pressure as follows: 1. Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch or the in-line high pressure fuel pump. 2. Crank engine for approximately ten seconds. Note: Engine may start and run for a short time. If so, crank engine an additional 5 seconds after engine stalls. 3. Re-connect the electrical connector that was disconnected in step 1 and disconnect battery ground cable. Alternative Method Some EFI vehicles have a port (fitting) on the fuel rail used for measuring fuel pressure. If so equipped, use the following method: Install fuel pressure relief tool No. T80L-9974-B or equivalent to measuring port on engine fuel rail. - Position drain hose in suitable container, then depress relief button. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications Firing Order 1-5-4-2-6-3-7-8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1750 Firing Order: Mechanical Specifications Location On Distributor FIRING ORDER: 1-5-4-2-6-3-7-8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cylinder Numbering And Distributor Location Location On Distributor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 1765 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 1766 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 1767 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 1768 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1769 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure Distributor Cap: Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 1775 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 1776 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure Ignition Rotor: Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 1781 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 1782 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 ...................................................................... ................................................................................................................. 9-20 Nm (7-15 ft-lbs) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1786 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications - Install each spark plug and tighten to 9-20 Nm (7-15 ft-lbs). Cylinder Numbering And Distributor Location Location On Distributor - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1793 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1794 Valve Clearance: Adjustments Fig. 2 Positioning crankshaft for valve clearance check Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1795 Fig. 3 Checking collapsed tappet clearance Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2, Fig. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5. b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7. 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6. 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent and check the clearance on the following valves: a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b. On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8. Valve Arrangement Front to Rear V8-302 Left Bank.................................................................................................................................. ...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank............................................. ..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank...................................................................................................................... .....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank...................................... .......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank................................................................................................................. ............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................ .............................................................................................................................................................. .I-E-I-E-I-E-I-E Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1804 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1805 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1806 Coolant: Technical Service Bulletins Engine Coolant - Recycled Coolant Not Authorized Article No. 90-4-10 COOLING SYSTEM - USE OF RECYCLED ENGINE COOLANT - SERVICE TIP FORD: 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA 1989-90 PROBE LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER MERKUR: 1985-90 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR MEDIUM/HEAVY TRUCK: 1984-90 C SERIES, F & B SERIES, L SERIES 1986-90 CARGO SERIES ISSUE: Ford Motor Company does not authorize the use of recycled engine coolant nor do they sanction the use of any machines or devices that recycle engine coolant. Recycled engine coolant is not equivalent to the factory fill OEM coolant, the Ford premium cooling system fluid (E2FZ-19549-AA) or the Ford heavy duty low silicate cooling fluid (E6HZ-19549-A). The quality of engine coolant degenerates with use. Recycling used engine coolant is very difficult to do without exposing the used coolant to additional foreign substances. Merely adding an additive to the coolant will not restore it. ACTION: Use new engine coolant that meets Ford Motor coolant specifications for the engine being serviced. Properly dispose of the used coolant. WARNING: THE DISPOSAL OF ALL USED ENGINE COOLANT MUST ALWAYS BE DONE IN ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE AND LOCAL LAWS AND REGULATIONS. PART NUMBER PART NAME CLASS E2FZ-19549-AA Coolant System Fluid - Ford V Premium E6HZ-19549-A Coolant System Fluid - Ford V Heavy Duty Low Silicate (For use in diesel powered med/hvy trucks) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4300 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity Without A/C Manual Transmission, Less Super Cooling ..................................................................................................................................................... 15.0 qts Automatic Transmission, Less Super Cooling ................................................................................................................................................ 17.5 qts Models With Super Cooling ................................................................................................................. ........................................................... 18.5 qts With A/C Manual Transmission .......................................................................................................................... ............................................................ 17.5 qts Automatic Transmission ........................................... ....................................................................................................................................... 18.5 qts Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1809 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to proper level. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection > Inspection > Page 1821 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 1826 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 1827 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1832 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1833 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine coolant temperature (ECT) sensor The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 1844 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 1845 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 1846 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 1847 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to proper level. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 1856 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 1868 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 1869 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine coolant temperature (ECT) sensor The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test > Page 1877 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics Thermostat: Technical Service Bulletins Cooling System - New System Diagnostics Article No. 93-24-8 11/24/93 ^ HESITATION - ROUGH IDLE - ENGINE COOLANT DOES NOT REACH NORMAL OPERATING TEMPERATURE - MEDIUM TRUCKS WITH 7.0L ENGINES ^ HESITATION/STALL DURING ACCELERATION OR DECELERATION ^ IDLE - ROUGH - ENGINE COOLANT DOES NOT REACH NORMAL OPERATING TEMPERATURE ^ HEATER/DEFROSTER - POOR HEATER OUTPUT - THERMOSTAT STUCK OPEN ^ COOLING SYSTEM - NEW DIAGNOSTICS FOR ENGINES THAT DO NOT REACH NORMAL OPERATING TEMPERATURE FORD: 1983-94 ESCORT 1984-87 EXP 1984-94 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1985-90 BRONCO II 1986-94 AEROSTAR 1988-94 F SUPER DUTY 1991-94 EXPLORER This TSB article is being republished in its entirety to include 1994 model year vehicles. ISSUE: Engine performance concerns such as hesitation or stall, rough idle, and/or poor fuel economy may be caused by the thermostat stuck in an open position or opening at a temperature lower than specified. ACTION: Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics > Page 1885 Use the following "Cooling System Diagnosis" procedure to diagnose a cooling system that may not be reaching normal operating temperature. Follow the "Thermostat Diagnosis" procedure to determine if the thermostat may be at fault. Check the thermostat without removing it from the vehicle by using Rotunda Service Coolant Temperature Monitor Harness 007-00064. A new cooling system diagnosis procedure has been developed for engines that do not reach normal operating temperature. A new thermostat diagnosis procedure also has been developed, using a new service coolant temperature monitor harness. NOTE: THIS PROCEDURE WILL DIAGNOSE ONLY COOLING SYSTEMS THAT MAY NOT BE REACHING NORMAL OPERATING TEMPERATURE. IT WILL NOT DIAGNOSE A THERMOSTAT THAT CAUSES AN ENGINE OVERHEAT CONDITION. NOTE: THE ESCORT/TRACER SPECIFIC APPLICATION FOR THIS ARTICLE IS AS FOLLOWS: ^ 1983-1990 Escort 1.9L and 1.6L ^ 1991-1994 Escort 1.9L ^ 1991-1994 Tracer 1.9L Only THERMOSTAT DIAGNOSIS NOTE: DISCONNECTING THE POWERTRAIN CONTROL MODULE (PCM) TO ATTACH A BREAKOUT BOX OR AN EEC IV MONITOR WILL ERASE THE ADAPTIVE LEARNING FROM MEMORY AND MAY "HIDE" A DRIVE CONCERN TEMPORARILY UNTIL THE ADAPTIVE LEARNING IS RE-LEARNED. NOTE: THIS PROCEDURE IS MOST ACCURATE IF PERFORMED INDOORS AT LESS THAN 100~F (38~C) AMBIENT TEMPERATURE. THIS TEST MAY BE PERFORMED WITH OR WITHOUT THE HOOD OPEN AND WITH THE ENGINE WARM OR COLD. CAUTION: ALWAYS VENT THE EXHAUST TO THE OUTSIDE WHEN PERFORMING THIS TEST. 1. Check the coolant level in the radiator and coolant recovery reservoir. 2. With the key in the "off" position, proceed as follows: a. Remove the engine coolant temperature (ECT) sensor harness connector. b. Attach Rotunda Service Coolant Temperature Monitor Harness 007-00064 as a jumper between the PCM and the ECT. c. Attach Rotunda 73 Digital Multimeter 105-00051 or equivalent to the thermostat monitor harness. Voltage values (0-5vdc) may now be Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics > Page 1886 monitored while the sensor retains its connection to the wiring harness. NOTE: A ROTUNDA NEW GENERATION STAR TESTER (NGS) 007-00500 OR THE ROTUNDA SERVICE BAY DIAGNOSTIC SYSTEM (SBDS) 001-00001 MAY BE USED TO MONITOR THE ECT ON VEHICLES EQUIPPED WITH DATA COMMUNICATIONS LINK (DCL). THE SBDS SEQUENCE TO USE FOR THE SCREEN IS "TOOLBOX - ELECTRONIC ENGINE CONTROL AND DCL - ITEM". 3. Vehicles equipped with electric engine cooling fan(s) must have a fan running during this test (high or low speed may be used). Two methods may be used to turn the fan(s) on: a. Disconnect the A/C compressor clutch power supply and turn the climate control to A/C "ON". Or b. Disconnect the power supply to the cooling fan and supply 12 volts direct to the fan connector from the battery. NOTE: A GROUND MAY BE REQUIRED FOR SOME APPLICATIONS. 4. Place transmission in "park" or "neutral". NOTE: RUNNING THIS TEST WITH THE VEHICLE IN GEAR OR WITH THE A/C COMPRESSOR CLUTCH ENGAGED (RUNNING) WILL CAUSE IMPROPER DIAGNOSIS 5. Start the engine and allow to idle throughout this test: a. Allow engine to run for 2 minutes, then record ECT voltage. b. From now on, record ECT voltage every 60 seconds. c. When the ECT voltage trend changes direction or changes only slightly (0.03 volts or less) from the previous reading, record this as the thermostat opening voltage. d. Use the "Voltage and Corresponding Temperature Chart" shown to obtain actual coolant temperatures. 6. If the opening voltage is GREATER than 0.75 volts (less than 18~ F/ 82~ C), or 0.85 volts (170~ F/ 77~ C) for 2.3L HSC engine only, replace the thermostat. Refer to the dealer Master Parts Catalog for correct thermostat usage. 7. If the thermostat opening voltage is LESS than 0.75 volts (greater than 180~ F/ 82~ C), or 0.85 volts (170~ F/ 77~ C) for 2.3L HSC engine only, the thermostat is good and should NOT be replaced. The "Cooling System Diagnosis Chart" should be referenced for further instructions. NOTE: The 10~ F opening temperature difference for the 2.3L HSC engine is due to the ECT sensor location. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-14-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 402000, 608000, 608400, 609000, 609400, 611000, 611500, 622000, 690000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter > Page 1895 Catalytic Converter: Description and Operation General Description Fig. 4 Single type catalytic converter with single substrate catalyst Fig. 5 Single type catalytic converter with dual substrate catalyst Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter > Page 1896 Fig. 6 Dual type catalytic converter The catalytic converter used on some vehicles, serves two purposes: it permits a faster chemical reaction to take place and although it enters into the chemical reaction, it remains unchanged, ready to repeat the process. The catalytic converter combines hydrocarbons (HC) and carbon monoxide (CO) with oxygen to form water (H2O) and carbon dioxide (CO2). The catalyst is structured in the form of a honeycomb monolithic composition, Figs. 4,5 and 6 . The catalyst consists of a porous substrate of an inert material, coated with platinum and other noble metals (the catalytically active materials.) This device, located in the exhaust system between the exhaust manifold and muffler, requires the use of heat shields, in some cases, due to its high operating temperatures. The heat shields are necessary to protect chassis components, passenger compartment and other areas from heat related damage. A small diameter fuel tank filler tube neck is incorporated to prevent the larger service station pump nozzle, used for leaded fuels, being inserted into the filler tube, thereby preventing system contamination. Since the use of leaded fuels contaminates the catalysts, deteriorating its effectiveness, the use of unleaded fuels is mandatory in vehicles equipped with catalytic converters. The catalytic converter can tolerate small amounts of leaded fuels without permanently reducing the catalyst effectiveness. There are basically three types of catalysts, the conventional oxidation catalyst (COC) containing Platinum (Pt) and Palladium (Pd) which are effective for catalyzing the oxidation reactions of hydrocarbons (HC) and carbon monoxide (CO) emissions. A three-way catalyst (TWC) containing Platinum (Pt) and Rhodium (RH), is not only effective for catalyzing the oxidation reactions of HC and CO emissions, but it also catalyzes the reduction of nitrogen oxides (NOx). A light off catalyst (LOC) is a single bed converter. It is arranged in series with the main catalytic converter assembly of COC and/or TWC as the aft member(s). This converter is designed to perform the very specialized function of exhaust emission control during engine warm-up when the main converter(s) is not yet at the temperature required for maximum efficiency. The LOC is designed to operate effectively in the high environmental conditions that exist near the manifold flange. The LOC is designed with a minimum heat sink effect and, provides minimum delay in warm-up of the main catalytic converter(s). The oxidation catalyst requires the use of a secondary air source which is provided by the pulse air or thermactor air injection systems. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1897 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 1898 Catalyst and Exhaust Systems Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair 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. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH Exhaust Pipe/Muffler Hanger: Customer Interest Vehicle - Moaning/Droaning at 55 to 65 MPH Article No. 85-4-39 MOAN/DRONE (5.0L/5.8L) - 2100 2800 RPM LIGHT TRUCK 1983-85 ECONOLINE, F150-350, BRONCO A moan/drone condition encountered at 55-65 mph may be a 2100-2800 engine rpm-related condition. Diagnosis and servicing will require a good road test followed by servicing of: 1) engine mounting, 2) exhaust hanger, 3) alternator pulley, and 4) alternator/thermactor braces depending on vehicle model and engine combination. 1. Road Test & Service Engine Mountings a. Road test vehicle. The vehicle should be equipped with a portable tachometer and driven at a road speed of 55-65 MPH (engine speed of 2100-2800 RPM). The A/C system should be in the "off" position and the vehicle should be evaluated on a smooth surfaced road or highway. If the road test verifies a "drone/ moan" condition, then the following procedures should be followed: Figure 25 b. On Bronco and F150-350 vehicles, loosen the No. 3 crossmember/rear engine support gussets at the attachment to the crossmember. If the gussets pull away from the crossmember, add shims to the gap. Retighten mounting bolts (install larger bolts if required). Refer to attached Figure 25). c. On model F150-350 (4x2)/E150-350 vehicles, inspect rear engine insulator (mount) for correct usage of Engineering Part E3TA-6D091-A/Service Part E0TZ-6068-B (white color code). Install correct part if required. Inspect mount for correct orientation of "capture strap" which could bind up the mount. With the vehicle on a two-post hoist, neutralize the front and rear engine support insulators (front and rear engine mounts) by loosening the front and rear engine mounts attaching bolts (attaching front mounts to support bracket and the rear mount to the No. 3 crossmember. Lower the vehicle and place safety stands under the front and rear axles. Start the engine and shift the automatic transmission into "drive" and back into "neutral" several times while engine is idling. With manual transmission, load engine by shifting transmission into forward and reverse gears and, with the parking brake partially applied, slip the clutch to load the engine. Raise the vehicle and remove the axle stands. Retorque front and rear engine mount attaching bolts (refer to Section 21-21 of 1983-1984 Light Truck Shop Manual for torque specifications). Lower vehicle and remove from hoist. d. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 2. Double Link Exhaust Hanger Installation - F - 4 x 2 Models Only a. 1980-83 Vehicles Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1910 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1911 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1912 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1913 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1914 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Vehicle - Moaning/Droaning at 55 to 65 MPH Article No. 85-4-39 MOAN/DRONE (5.0L/5.8L) - 2100 2800 RPM LIGHT TRUCK 1983-85 ECONOLINE, F150-350, BRONCO A moan/drone condition encountered at 55-65 mph may be a 2100-2800 engine rpm-related condition. Diagnosis and servicing will require a good road test followed by servicing of: 1) engine mounting, 2) exhaust hanger, 3) alternator pulley, and 4) alternator/thermactor braces depending on vehicle model and engine combination. 1. Road Test & Service Engine Mountings a. Road test vehicle. The vehicle should be equipped with a portable tachometer and driven at a road speed of 55-65 MPH (engine speed of 2100-2800 RPM). The A/C system should be in the "off" position and the vehicle should be evaluated on a smooth surfaced road or highway. If the road test verifies a "drone/ moan" condition, then the following procedures should be followed: Figure 25 b. On Bronco and F150-350 vehicles, loosen the No. 3 crossmember/rear engine support gussets at the attachment to the crossmember. If the gussets pull away from the crossmember, add shims to the gap. Retighten mounting bolts (install larger bolts if required). Refer to attached Figure 25). c. On model F150-350 (4x2)/E150-350 vehicles, inspect rear engine insulator (mount) for correct usage of Engineering Part E3TA-6D091-A/Service Part E0TZ-6068-B (white color code). Install correct part if required. Inspect mount for correct orientation of "capture strap" which could bind up the mount. With the vehicle on a two-post hoist, neutralize the front and rear engine support insulators (front and rear engine mounts) by loosening the front and rear engine mounts attaching bolts (attaching front mounts to support bracket and the rear mount to the No. 3 crossmember. Lower the vehicle and place safety stands under the front and rear axles. Start the engine and shift the automatic transmission into "drive" and back into "neutral" several times while engine is idling. With manual transmission, load engine by shifting transmission into forward and reverse gears and, with the parking brake partially applied, slip the clutch to load the engine. Raise the vehicle and remove the axle stands. Retorque front and rear engine mount attaching bolts (refer to Section 21-21 of 1983-1984 Light Truck Shop Manual for torque specifications). Lower vehicle and remove from hoist. d. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 2. Double Link Exhaust Hanger Installation - F - 4 x 2 Models Only a. 1980-83 Vehicles Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1920 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1921 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1922 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1923 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe/Muffler Hanger: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 1924 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Engine Control Module: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 1932 Engine Control Module: Locations Under right side of instrument panel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1935 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1936 Fig. 133 EEC-IV connector terminal identification. V8-302 & 351 FBC E Series Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 1937 Engine Control Module: Description and Operation Fig. 6 Electronic control assembly The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration assembly, Fig. 6. The processor receives input signals from the various sensors. The information obtained is used by the processor to activate engine control systems to obtain optimum emission control and performance. The calibration assembly is a permanent memory device that contains information. The processor applies the sensor inputs to the stored information to determine when and how long the various control systems should be applied. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1941 Main Relay (Computer/Fuel System): Description and Operation Fig. 12 EEC relay type, system application & relay locations EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine applications. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations EGR Control Module: Locations Behind LH Side Of Instrument Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1962 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Locations Fuel Shut-off Solenoid Relay: Locations LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1969 Main Relay (Computer/Fuel System): Description and Operation Fig. 12 EEC relay type, system application & relay locations EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine applications. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 861125 > Jun > 86 > Engine - Cranks/No Start/Stalls At Idle Ignition Control Module: Customer Interest Engine - Cranks/No Start/Stalls At Idle Article No. 86-11-25 STALL IDLE ALL EEC IV WITH TFI NO START - ENGINE CRANKS ALL EEC IV WITH TFI FORD 1984-86 ALL WITH EEC IV LINCOLN-MERCURY 1984-86 ALL WITH EEC IV Low mileage vehicles may experience an intermittent no start or stall at idle. This concern can be experienced on all 1986 production vehicles or on vehicles that have had a TFI IV Ignition Module Service replaced using part number E3EF-12A297-AlA. If an internal short circuit occurs in some recently manufactured TFI IV Ignition Modules (part number suffix A1A), the Hall sensor may become shorted to ground. At the moment of short, the EEC processor will not receive a PIP signal and the vehicle will not start or may stall at idle. The concern has been isolated to TFIIV Ignition Modules with a part number that contains the A1A suffix and a manufacturing date code of 5FOl (85 June 01) through 6D17 (86 April 17). The date code is heat stamped on the module connector shroud. 1. Follow normal Shop Manual, Volume H service procedures. NOTE: This concern can be an intermittent condition and Intermittent Diagnostic Procedures may have to be followed. 2. If replacement of the TFI IV Ignition Module is indicated, assure that service replacement part contains a part number with a suffix of A2A or one with a suffix of A1A and a manufacturing date code before 5FOl or after 6D17. PART NUMBER PART NAME CLASS E43Z-12A297-A TFI Ignition Module A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 1265OD15 TIME: 1.0 Hr. - 1.9L EFI 0.9 Hr. -All others DLR. CODING: Basic Part No. 12A297 - Code: N2, N9, Pl Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: Customer Interest Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 1987 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 1988 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure Ignition Control Module: All Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 1994 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 1995 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2000 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2001 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2002 TFI-IV Part 2 Test 3 Stator - TFI Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2003 TFI-IV Part 2 Test 4 & 5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2004 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2005 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2006 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2007 TFI-IV Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2008 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2009 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2010 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2011 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2012 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2013 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2014 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2015 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2016 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2017 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2018 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2019 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2020 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2021 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2022 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 861125 > Jun > 86 > Engine - Cranks/No Start/Stalls At Idle Ignition Control Module: All Technical Service Bulletins Engine - Cranks/No Start/Stalls At Idle Article No. 86-11-25 STALL IDLE ALL EEC IV WITH TFI NO START - ENGINE CRANKS ALL EEC IV WITH TFI FORD 1984-86 ALL WITH EEC IV LINCOLN-MERCURY 1984-86 ALL WITH EEC IV Low mileage vehicles may experience an intermittent no start or stall at idle. This concern can be experienced on all 1986 production vehicles or on vehicles that have had a TFI IV Ignition Module Service replaced using part number E3EF-12A297-AlA. If an internal short circuit occurs in some recently manufactured TFI IV Ignition Modules (part number suffix A1A), the Hall sensor may become shorted to ground. At the moment of short, the EEC processor will not receive a PIP signal and the vehicle will not start or may stall at idle. The concern has been isolated to TFIIV Ignition Modules with a part number that contains the A1A suffix and a manufacturing date code of 5FOl (85 June 01) through 6D17 (86 April 17). The date code is heat stamped on the module connector shroud. 1. Follow normal Shop Manual, Volume H service procedures. NOTE: This concern can be an intermittent condition and Intermittent Diagnostic Procedures may have to be followed. 2. If replacement of the TFI IV Ignition Module is indicated, assure that service replacement part contains a part number with a suffix of A2A or one with a suffix of A1A and a manufacturing date code before 5FOl or after 6D17. PART NUMBER PART NAME CLASS E43Z-12A297-A TFI Ignition Module A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 1265OD15 TIME: 1.0 Hr. - 1.9L EFI 0.9 Hr. -All others DLR. CODING: Basic Part No. 12A297 - Code: N2, N9, Pl Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: All Technical Service Bulletins Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 2039 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 2040 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Ignition Control Module: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure Ignition Control Module: All Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 2050 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 2051 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2056 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2057 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2058 TFI-IV Part 2 Test 3 Stator - TFI Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2059 TFI-IV Part 2 Test 4 & 5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2060 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2061 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2062 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2063 TFI-IV Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2064 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2065 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2066 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2067 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2068 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2069 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2070 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2071 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2072 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2073 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2074 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2075 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2076 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2077 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 2078 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Ignition Control Module: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2087 Component Locations - RH Side Of Engine TFI-IV Ignition Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2088 Ignition Control Module: Description and Operation Thick Film Ignition Module The TFI IV ignition module, Fig. 14, has six connector pins at the wiring harness that supplies the following signals: Run Crank (start) Tach (coil) PIP (crankshaft position to ECA) Spark output (SPOUT from ECA) Internal ground from the ECA to the distributor Ignition System The TFI IV module supplies the spark to the distributor through the ignition coil and calculates the duration. It receives its control signal from the ECA (SPOUT) Fig. 29. NOTE: Some later models use a remote module (Closed Bowl Distributors/CBD). It is located in the engine compartment (Refer to "COMPONENT LOCATIONS"). The operation is essentially the same with the exception of the CBD has a wiring harness between the ignition module and the distributor. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2089 Ignition Control Module: Service and Repair Open Bowl Distributor 1. Remove distributor cap and adapter. Position cap and wires aside. 2. Disconnect TFI wiring. 3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type hold-down bolt, if equipped. 4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2. 5. Pull right side of module down distributor mounting flange and then back up to disengage module terminals from connector in distributor base. Module may then be pulled toward flange and away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI module toward distributor flange, as pins at distributor/module connector will break otherwise. 6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease D7AZ-19A331-A, or equivalent. 7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly toward distributor bowl and securely engage 3 distributor connector pins. 8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs. 9. Install distributor on engine. 10. Install distributor cap and adapter. 11. Connect TFI wiring. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2090 12. Check and, if necessary adjust engine timing according to decal. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, then translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor constantly monitors air temperature entering the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 2099 Barometric Pressure Sensor: Locations RH Fender Apron At Wheel Well Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation Fig. 19 Ignition barometric pressure switch. 1984-87 1984---87 This switch, Fig. 19, controls spark timing and/or other electrical devices according to barometric pressure changes. Calibration resistors in the switch assembly cause the ignition module to vary the spark timing. Spark timing is advanced for vehicle operation above a predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some switch assemblies control both spark timing and another device while other switch assemblies control only one or the other. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing Fig. 43 Ignition barometric pressure switch resistance chart. 1985---87 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2109 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 2113 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 2114 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine coolant temperature (ECT) sensor The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2119 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2124 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2125 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2126 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2127 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2128 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2129 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2130 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2131 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2132 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2133 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2134 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2135 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2136 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2137 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2138 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2139 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2140 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2141 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2142 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2143 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2144 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2145 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2146 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2147 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2148 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2149 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2150 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2151 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2152 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2153 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2154 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2155 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2156 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2157 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations EGR Valve Position Sensor: Component Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations > Page 2160 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 2164 Intake Air Temperature Sensor: Description and Operation Fig. 2 Air charge temperature (ACT) sensor This sensor, Fig. 2, provides the EFI system with air/fuel mixture temperature information. The air charge temperature sensor is used both as a density corrector to air flow calculation and to proportion the cold enrichment fuel flow. This sensor is similar in construction to the engine coolant temperature sensor and is mounted on an intake manifold runner or on the air cleaner. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Manifold Pressure/Vacuum Sensor: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service > Page 2172 Manifold Pressure/Vacuum Sensor: Technical Service Bulletins EEC IV MAP Sensor - New Part Numbers/Applications Article No. 85-12-17 MAP SENSOR - EEC IV - NEW PART NUMBERS/APPLICATIONS FORD 1984-85 MUSTANG, LTD, TEMPO, THUNDERBIRD, CROWN VICTORIA LINCOLN-MERCURY 1984-85 CAPRI, MARQUIS, TOPAZ, COUGAR, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN LIGHT TRUCK 1984-85 RANGER, BRONCO II, E150/250, F150/250, BRONCO New MAP sensor part numbers have recently been released. The MAP sensor formerly referred to as the Yellow Dot MAP is now identified with part number E43Z-9F479-B. The Yellow Dot is no longer used for identification. The MAP sensor used for 3.8L CFI-SD applications will be identified as E5SZ-9F479-A. The chart lists the correct MAP sensor to the correct EEC IV application. PART NUMBER PART NAME CLASS E5SZ-9F479-A MAP Sensor C E43Z-9F479-B MAP Sensor A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 2173 MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 2174 Manifold Pressure/Vacuum Sensor: Locations On right front fender well. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2179 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2180 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2181 Oxygen Sensor: Description and Operation Fig. 8 Exhaust gas oxygen (EGO) sensor The exhaust gas oxygen sensor supplies the ECA with a signal which indicates either a rich or lean condition during engine operation. The sensor is threaded into the center of the exhaust manifold on 4-140 and 6-300 engines, threaded into the rear of left and right exhaust manifold assemblies on V6-171 engine or threaded into the rear right exhaust manifold assembly on V8-302 and 351 engine, Fig. 8. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Power Steering Pressure Switch: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Full Close Switch > Component Information > Description and Operation Throttle Full Close Switch: Description and Operation The idle tracking switch, is a mechanically operated electric switch held open by the throttle linkage when the throttle is closed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2193 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2194 OASIS CODES: 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2195 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2196 THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2197 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box > Page 2200 Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > Page 2201 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect throttle position sensor electrical connector. 3. Scribe a reference mark across edge of sensor and to throttle body to ensure correct position during installation. 4. Remove two sensor attaching screws, then the sensor and gasket. 5. Reverse procedure to install, noting the following: a. Slide the throttle position sensor rotary tangs into position over throttle shaft blade, then rotate sensor clockwise to align scribe marks. b. Torque sensor attaching screws to 11 - 16 inch lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vacuum Switch > Component Information > Locations Vacuum Switch: Locations RH Fender Apron At Wheel Well Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications VEHICLE SPEED SENSOR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2208 Vehicle Speed Sensor: Locations At LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 2211 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2217 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2218 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2219 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2220 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2221 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2222 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2223 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2224 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2225 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2226 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2227 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2228 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2229 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2230 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2231 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2232 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2233 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2234 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2235 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2236 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2237 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2238 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2239 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2240 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2241 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2242 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2243 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2244 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2245 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2246 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2247 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2248 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2249 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2250 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations EGR Valve Position Sensor: Component Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations > Page 2253 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: Customer Interest Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 2262 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: All Technical Service Bulletins Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 2268 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, then translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor constantly monitors air temperature entering the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > Tank Selector Relay Fuel Tank Selector Switch: Locations Tank Selector Relay Left Rear Corner Of Engine Compartment (next to fuel cut-off relay). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > Tank Selector Relay > Page 2277 Fuel Tank Selector Switch: Locations Fuel Tank Selector Switch LH Side Of I/P Near Fuse Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations Under I/P Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 2283 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Description and Operation Throttle Full Close Switch: Description and Operation The idle tracking switch, is a mechanically operated electric switch held open by the throttle linkage when the throttle is closed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2291 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2292 OASIS CODES: 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2293 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2294 THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2295 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box > Page 2298 Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > Page 2299 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect throttle position sensor electrical connector. 3. Scribe a reference mark across edge of sensor and to throttle body to ensure correct position during installation. 4. Remove two sensor attaching screws, then the sensor and gasket. 5. Reverse procedure to install, noting the following: a. Slide the throttle position sensor rotary tangs into position over throttle shaft blade, then rotate sensor clockwise to align scribe marks. b. Torque sensor attaching screws to 11 - 16 inch lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure Hall Effect Sensor: Technical Service Bulletins Distributor Stator - Replacement Procedure Article No. 85-4-21 DISTRIBUTOR UNIVERSAL - ALL - STATOR REPLACEMENT FORD 1983-1985 ESCORT, EXP, TEMPO, CROWN VICTORIA, MUSTANG, THUNDERBIRD, LTD LINCOLN-MERCURY 1983-1985 LYNX, TOPAZ, CAPRI, COUGAR, MARQUIS, GRAND MARQUIS, LINCOLN, CONTINENTAL, MARK VII LIGHT TRUCK 1984-1985 BRONCO II, 1983-1985 RANGER, 1985 F-100 THRU F-250, 1984-1985 ECONOLINE The stator assembly (-12A112-) is now a serviceable component for the above vehicles. The procedures to be used when servicing the stator assembly are as follows: 1.6L EFI and 1.6L EFI T/C DISTRIBUTOR W/TFI STATOR ASSEMBLY REPLACEMENT Removal 1. Using a screwdriver, remove the distributor cap and position it and the attached wires aside so as not to interfere with work area. 2. Disconnect the TFI module from the harness. 3. Remove the distributor from the engine block. 4. Remove the rotor. 5. Remove the drive coupling spring with a small screwdriver or ice pick. Take care not to damage the drive coupling or spring. 6. a. Using an air hose, blow dirt and oil from the drive end of the distributor. b. Put a small paint dot on the drive coupling and the shaft to note orientation for re-assembly. Figure 31 - Distributor Support Tool c. Place the distributor support tool (Figure 31) in a vise and tighten or open the vise jaws wide enough to let pin drop out of the coupling but not so wide that the coupling is not supported. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2315 d. Line-up the drive pin with the slot in the base. 7. With someone holding the distributor steady on the support tool or vise, use a 5/32 inch diameter drift and hammer to drive the pin out of the shaft. 8. Remove the distributor from the fixture. Remove the drive coupling from the fixture and place aside for re-assembly. 9. Before removing the shaft from the base, check for burrs on the end of the shaft and especially around the drive pin hole. If burrs are present, polish the shaft with emery paper and wipe clean before removing the shaft from the base to prevent damage to the lip seal and bushing in the base. 10. After assuring that there are no burrs, remove shaft assembly by gently pulling up on the shaft plate. 11. Remove the two screws holding the module to the base. 12. Remove the module. Wipe grease from the base and module, keeping surfaces free of dirt. 13. Remove the octane rod retaining screw. 14. Remove the octane rod assembly. 15. Remove the two screws retaining the stator connector in the bowl of the distributor. (Retain the screws for re-assembly.) 16. Remove the stator assembly from the top of the bowl, by gently lifting up. 17. Inspect the base bushing for wear or signs of excess heat concentration, replace the complete distributor assembly if damaged. 18. Inspect the shaft oil seal for tears or cuts; replace the complete distributor assembly if oil seal is damaged. 19. Carefully check the spring retainer that holds the shaft oil seal against the shaft - it must be present and have no kinks or breaks. Replace spring if necessary. 20. Inspect the base "O" ring for cuts or damage and replace the "O" ring if necessary. 21. Inspect base casting for cracks and wear. Replace complete distributor assembly if damage is found. Re-assembly and Installation 1. Place the stator over the bushing and press down to seat. 2. Place the stator connector in position - tab should fit in the notch on the base and the fastening eyelets should be aligned with their screw holes. 3. Position the wires away from moving parts. 4. Reinstall the two stator screws and torque to specification (25-35 in.lbs.). 5. With the seal on the octane rod, insert in holes. Reinstall the octane rod through the base octane rod hole. 6. Place the end of the octane rod onto the same post as the original stator only (one post should easily fit in the octane rod hole). 7. Reinstall the octane rod screw and torque to specification (25-35 in.lbs.). 8. Wipe the back of the module and the distributor module mounting face free of all dirt. 9. Apply grease (No. WA10) to back of the module and spread evenly (thin, even coverage). 10. Turn the distributor base upside down so that the stator connector is in full view. 11. Insert the module, being sure that the three module pins are inserted into the stator connector. 12. Fully seat the module into the connector and against the base. 13. Reinstall the module screws and torque to specification (25-35 in.lbs.). 14. Apply a light coat of M2C162A oil to the distributor shaft below the armature. NOTE: Do not over-lubricate. 15. Insert the shaft assembly through the base bushing. 16. Place the drive coupling over the shaft and line up the paint dots that were made during disassembly. Start the pin into the drive coupling and shaft. 17. With someone holding the distributor steady on the support tool or vise, drive the pin into the shaft until the end of the pin is flush with the step in the drive coupling. 18. Check for free movement of the drive coupling on the pin and verify that the pin does not extend beyond the step in the coupling in either direction. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2316 19. Remove the distributor from the fixture and check for free rotation. 20. Install the drive coupling spring in the groove on the drive coupling. 21. Install the distributor assembly in the engine. 22. Install the distributor cap and rotor. 23. Install the TFI module connector. UNIVERSAL DISTRIBUTOR W/EEC (OTHER THAN 1.6L) STATOR ASSEMBLY REPLACEMENT NOTE: Do not attempt to replace the stator without an arbor press. Removal 1. Using a screwdriver, remove the distributor cap, position the cap and wires aside so as not to interfere with the work area. - Remove TFI module connector. 2. Remove distributor from block per the distributor removal procedure. 3. Remove rotor. 4. Remove the two screws holding the TFI module to the base. 5. Remove the module, wipe the grease from the base and module, keeping the surfaces free of dirt. 6. If the distributor uses the push-on rotor, remove the two screws holding the armature and remove the armature. NOTE: Hold the gear to loosen the armature screws, do not hold the armature. 7. To ease re-assembly, mark with a felt tip pen, the armature, gear and collar if present (Refer to the following chart.) to note orientation. 8. Remove and discard pins in gear and collar if present (Refer to chart.). Figure 32 - Bearing Removal Tool 9. Invert the distributor and place in the Axle Bearing/Seal Plate (Tool D84L-950-A) and press off the gear using the Bearing Removal Tool (T75L-1165-B) as shown in Figure 32. 10. Deburr and polish shaft with emery paper and wipe such that the shaft slides out freely from distributor base. 11. Remove shaft assembly. 12. Remove thrust washer from distributor shaft and retain. 13. Remove octane rod retaining screw and retain. 14. Remove octane rod assembly and retain. GEAR GEAR THRUST ROLL PIN COLLAR ENGINE GEAR PIN WASHER EXTRUSION COLLAR PIN 2.3L HSC 67555-S FLUSH Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2317 2.3L OHC 67555-S FLUSH 2.8L 67575-S FLUSH 3.8L 67555-S FLUSH X 67555-S 4.9L 67775-S2 X EXTRUDE EVENLY, BOTH SIDES 5.0L 67555-S FLUSH X 67555-S 6.1L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 7.0L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 7.5L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 15. Remove two stator assembly screws and retain. 16. Remove stator assembly from top of bowl. 17. Inspect base bushing for wear or signs of excess heat concentration, replace complete distributor assembly if damaged. 18. Inspect base "O" ring for cuts or damage and replace "O" ring if necessary. 19. Inspect base for cracks and wear. Replace complete distributor assembly if damage is found. Re-assembly and Installation 1. Place the stator assembly over the bushing and press down to seat. 2. Place the stator connector in position - tab should fit in notch on base and fastening eyelets aligned with screw holes. 3. Position wires away from moving parts. 4. Install the two stator screws and torque to specification (25-35 in.lbs.). 5. Reinstall the octane rod, inserting rod through the base hole. 6. Place end of octane rod onto the same post as the original stator. Only one post should easily fit in rod hole. 7. Firmly seat octane rod seal into housing. 8. Reinstall the octane rod screw and torque to specification (25-35 in./lbs.). 9. If required, reinstall the thrust washer on top of the bushing. 10. Apply a light coat of ESF-M2C70-A to the distributor shaft below the armature. 11. Insert the shaft through the base bushing. 12. Place the collar, if required, over the shaft and line up mark on armature and collar to aid alignment with original drill hole. Use a drift punch to assure proper alignment. NOTE: Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, the collar may be 180 degrees out of alignment on the shaft. Rotate the collar on the shaft one half rotation and recheck. 13. Insert new roll pin (Part No. 67555-S) through collar and shaft. Pin should be flush with both sides of collar when seated. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2318 Figure 33 - Push On Rotor Figure 34 - Screw Down Rotor 14. If the distributor uses a push-on rotor, place a 1/2 inch deep well socket over the shaft (Figure 33), invert and place on arbor plate. 14a. If the distributor uses a screw-down rotor, invert and place on arbor plate (Figure 34). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2319 Figure 35 - Press Gear 15. Place the distributor gear on the shaft and line up the mark on the armature and gear. NOTE: The hole in the shaft and gear must be lined up as accurately as possible to assure ease of roll pin insertion. 16. Place a 5/8 inch deep well socket over the shaft and gear (Figure 35) and press gear to align with original drill hole. NOTE: If the gear holes do not align, the gear must be removed and repressed on. A drift punch will not align the holes. As in the collar, the holes should align. 17. Insert new roll pin (Refer to chart following Step 7 in the Removal Procedure) through gear and shaft. Pin should have proper extrusion, as referenced in same chart. 18. If the armature was removed, replace and torque screws to 25-35 in.lbs. 19. Check distributor for free movement over full rotation of shaft. NOTE: If the armature hits the stator; replace the entire distributor. 20. Wipe back of module and distributor module mounting face free of all dirt. 21. Apply grease (No. WA10) to the back of the module and spread evenly (thin, even coverage). 22. Turn the distributor base upside down such that the stator connector is in full view. 23. Insert the module and watch that the three module pins are inserted into the stator connector. Fully seat the module into the connector and against base. 24. Reinstall two module screws and torque to specification (25-35 in.lbs.). 25. Reinstall the distributor into block per distributor replacement procedure. 26. Connect TFI module to wiring harness. 27. Replace rotor and torque screws to specification. 28. Replace cap and torque screws to specification. 29. Retime engine. PART NUMBER PART NAME CLASS 67555-S Pin BS 67775-S2 Pin RS E3ZZ-12A112-C Stator A OTHER APPLICABLE ARTICLES: None Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2320 WARRANTY STATUS: "INFORMATION ONLY" OPERATION: STATOR REPLACE 12112D1 TIME: 1.6L Engine 0.6 HR. All Others 0.5 HR. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2321 Hall Effect Sensor: Technical Service Bulletins Engine - No Start/Idles Rough/Knock When Cold Article No. 85-7-11 (Supercedes Article No. 85-4-20) 04/04/85 NO START - ALL EEC IV IDLE ROUGH - ALL EEC IV - COLD SPARK KNOCK - ALL EEC IV COLD FORD: 1984-85 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, LTD, CROWN VICTORIA LINCOLN-MERCURY: 1984-85 LYNX, LN7 TOPAZ, CAPRI, COUGAR, MARQUIS, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK: 1984-85 BRONCO II; 1983, 84, 85 RANGER; 1984-85 F100 THRU F-250; 1984-85 ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2322 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2323 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2324 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2325 This article is being republished to revise Test 5. The above concerns can be caused by the distributor Hall Effect sensor. When the above concerns occur only at cold temperatures and the engine starts and runs satisfactorily when warm, use the first diagnostic procedure. If the concern is no start, use the second procedure. If a T.F.I. is removed from the distributor and the stator connector is soft or mushy, replace the stator. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" TFI Module Side of the SPOUT Connector Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 2326 Terminal Voltage Measurement Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 2327 Hall Effect Sensor: Description and Operation Profile Ignition Pickup The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA. PIP Sensor COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator, Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the output is high. When the signal is high the output is low. This output then goes to the Schmitt trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 2328 PIP Signal Operation OPERATION The output signal to the Darlington amplifier is high when the window (on the armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington amplifier (switch on). Hall Effect Sensor In other words when one of the windows or openings is in the gap between the Hall device and the permanent magnet, the field stays strong and the voltage is high since the magnetic path is complete from the magnet, through the Hall device, and back to the magnet. In this case the switch is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the TFI module if the SPOUT signal from the ECA is lost. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 2329 Signature PIP SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature profile ignition pickup signal. The regular type armature used for the PIP signal has the same size tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors. This system is used on cars and trucks where the ECA needs to know when to pulse certain injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the No. 1 cylinder needs to be supplied with fuel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 2338 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 2344 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 2345 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Carburetor Fuel Pressure: Specifications Carburetor 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Carburetor > Page 2354 Fuel Pressure: Specifications Fuel Injection FUEL SYSTEM SPECIFICATIONS Pressure Key On Engine Off ............................................................................................................................... ................................................... 35-45 psi Engine Idling .................................................................... ....................................................................................................................... 28-38 psi Volume A minimum of 170 ml (5.6 oz) in 10 seconds. WARNING: Fuel supply lines will remain pressurized for some period of time after the engine is shut off. Before opening the fuel system, relieve the fuel pressure. FUEL PRESSURE RELIEF PROCEDURE - Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch, or the in-line high pressure fuel pump. - Crank engine for about ten seconds. NOTE: Engine may start and run for a short time. If so, crank engine an additional five seconds after engine stalls. - Reconnect the electrical connector that was disconnected in the first step. - Disconnect negative battery cable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2355 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments Fig. 1 Propane enrichment specifications Refer to Propane Enrichment Chart, Fig. 1, when adjusting. 1. Apply parking brake, block wheels, disconnect automatic brake release, if equipped, and plug vacuum connection. 2. Connect suitable tachometer to engine. 3. If vehicle is equipped with hot idle compensator (HIC), ensure HIC is in closed position and remains closed throughout test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to ensure HIC is closed. 4. On 1983 models except V8-302 engine with 2150A-2V feedback carburetor, proceed as follows: a. Disconnect fuel evaporative purge return hose, if equipped, and plug connection. b. Disconnect fuel evaporative purge hose, if equipped, at air cleaner and plug nipple. 5. On all vehicles, disconnect flexible fresh air tube from air cleaner duct or adapter, then, using tool T75L-9600-A or equivalent, insert tool hose approximately 3/4 of the way into duct or fresh air tube. Secure hose with tape as necessary. 6. On vehicles equipped with thermactor systems, revise dump valve vacuum hoses as follows: a. On dump valves with two vacuum fittings, disconnect and plug hoses. b. On dump valves with one fitting or combination air bypass/air control valve, except vehicles with feedback carburetor, remove hose at dump valve and plug hose. Connect slave hose from dump valve vacuum fitting to an intake manifold vacuum fitting. c. On V8-351 engine equipped with 4180C-4V carburetor, disconnect and plug vacuum hose to dump valve. 7. On 1984 - 85 models with feedback carburetor, disconnect battery ground cable for at least 10 seconds. 8. On all models with feedback carburetor, proceed as follows: a. Disconnect electrical connector at engine coolant temperature sensor. b. Disconnect and plug hose from manifold absolute pressure (MAP) sensor. c. Disconnect and plug hose from carburetor vacuum operated throttle modulator (VOTM). d. Connect vacuum pump to manifold port of MAP sensor, evacuate to at least 20 inches Hg. and hold. e. Start engine. Leave all vacuum hoses attached to air cleaner assembly when moving assembly to perform carburetor adjustments. The air cleaner assembly must be in place when measuring engine speeds. Prolonged engine idling may cause catalyst overheating and excessive underbody temperatures. 9. On all vehicles, ensure that ignition timing is set to specifications. 10. Check engine curb idle speed or A/C-OFF RPM, adjusting as necessary. Remove PCV valve from grommet and allow PCV to draw underhood air during idle fuel mixture check. 11. With transmission in neutral, run engine at approximately 2500 RPM for 15 seconds for each mixture check. 12. With engine idling at normal operating temperature, place transmission in specified gear, gradually open propane tool valve and watch for engine speed gain, if any, on tachometer. 13. When engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. The propane cartridge must be in vertical position. If engine speed will not drop off, check propane cartridge gas supply. If necessary, repeat steps 11 through 13 with a new propane cartridge gas supply. 14. Compare measured speed gain to specified speed gain. 15. If measured speed gain is within specifications, proceed to step 20. If carburetor assembly is equipped with a tamper resistant idle adjustment feature, the carburetor must be removed from the vehicle. If idle fuel mixture adjustment is necessary, adjust mixture according to reset RPM specification. 16. If measured speed gain is zero and minimum speed gas specification is zero, proceed to step 19. 17. If measured speed gain is higher than specification, turn mixture screw(s) counterclockwise in equal amounts while simultaneously repeating steps Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments > Page 2359 10 through 13 until measured speed rise meets reset RPM specification. After final adjustment, proceed to step 20. 18. If measured speed gain is lower than speed gain specifications, turn idle mixture screw(s) clockwise in equal amounts while simultaneously repeating steps 10 through 13 until measured speed rise meets reset RPM specifications. After final adjustment, proceed to step 20. 19. If there is no RPM rise and the minimum speed gain specification is zero RPM, perform speed drop test as follows. Speed drop test information is specified with the artificial enrichment requirements whenever minimum speed gain specification is zero RPM. a. While observing tachometer, adjust mixture screw(s) clockwise by number of turns specified for speed drop test, noting drop in engine speed. b. If measured speed drop is equal to or drops off by more than the speed drop specification, return mixture screw(s) to position before adjustment and proceed to step 20. c. If measured speed drop is less than specified minimum speed drop specification, leave mixture screw(s) in adjusted position and repeat steps 10 through 19. 20. Install tamper resistant feature for carburetor idle fuel air adjustment. 21. Install PCV valve in grommet. 22. On vehicles equipped with feedback carburetor, proceed as follows: a. Connect electrical connector to engine coolant temperature sensor. b. Connect hose to MAP sensor. c. Connect hose to VOTM. d. Check curb idle speed and adjust to specification. 23. Remove all test equipment, reconnect all system components and install air cleaner. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2368 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2369 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2370 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2371 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2372 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2373 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2374 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2375 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2376 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2377 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2378 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2379 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2380 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2381 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2382 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2383 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2384 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2390 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2391 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2392 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2393 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2394 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2395 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2396 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2397 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2398 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2399 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2400 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2401 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2402 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2403 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2404 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2405 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2406 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2407 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2408 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2409 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2410 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2411 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2412 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2413 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2414 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2415 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2416 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2417 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2418 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2419 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2420 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2421 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2422 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2423 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2424 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2425 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2426 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2427 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2428 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2429 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2430 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2431 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2432 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2433 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2434 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2435 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2436 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2437 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2438 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2439 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2440 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2441 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 2442 FUEL INJECTED MODEL SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). Set parking brake and block wheels. - Bring engine to normal operating temperature (upper radiator hose hot). - Disconnect the electric connector on the evaporative cannister purge solenoid. - Disconnect and plug the vacuum hose to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission in "DRIVE" position. - Loosen the Throttle Solenoid Positioner (TSP) dashpot mounting bracket hold-down screw. - 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. - Retighten the TSP dashpot mounting bracket hold-down screw. - Remove the plug from the vacuum hose to the VOTM kicker and reconnect. - Reconnect the electric connector on the evaporative cannister purge solenoid. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 2445 Idle Speed: Adjustments Fast Idle Speed FAST IDLE SPEED ADJUSTMENT - Place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the electric connector on the evaporative cannister purge solenoid. - Disconnect the vacuum hose at the EGR valve and plug. - Place the fast idle adjustment mechanism on specified step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove the plug from the EGR vacuum hose and reconnect. Reconnect the electric connector on the evaporative cannister purge solenoid. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: FUEL SUPPLY LINES ON EFI ENGINES WILL REMAIN PRESSURIZED FOR SOME PERIOD OF TIME AFTER THE ENGINE IS SHUT OFF. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. FUEL SYSTEM PRESSURE RELIEF - EFI ENGINES Before opening the fuel system on vehicles with EFI engines, relieve fuel pressure as follows: 1. Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch or the in-line high pressure fuel pump. 2. Crank engine for approximately ten seconds. Note: Engine may start and run for a short time. If so, crank engine an additional 5 seconds after engine stalls. 3. Re-connect the electrical connector that was disconnected in step 1 and disconnect battery ground cable. Alternative Method Some EFI vehicles have a port (fitting) on the fuel rail used for measuring fuel pressure. If so equipped, use the following method: Install fuel pressure relief tool No. T80L-9974-B or equivalent to measuring port on engine fuel rail. - Position drain hose in suitable container, then depress relief button. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications Firing Order 1-5-4-2-6-3-7-8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2454 Firing Order: Mechanical Specifications Location On Distributor FIRING ORDER: 1-5-4-2-6-3-7-8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cylinder Numbering And Distributor Location Location On Distributor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 2469 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 2470 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 2471 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 2472 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2473 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure Distributor Cap: Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 2479 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 2480 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure Ignition Rotor: Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 2485 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 2486 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 ...................................................................... ................................................................................................................. 9-20 Nm (7-15 ft-lbs) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2490 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications - Install each spark plug and tighten to 9-20 Nm (7-15 ft-lbs). Cylinder Numbering And Distributor Location Location On Distributor - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2497 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2498 Valve Clearance: Adjustments Fig. 2 Positioning crankshaft for valve clearance check Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 2499 Fig. 3 Checking collapsed tappet clearance Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2, Fig. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5. b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7. 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 3, and check the clearance on the following valves: a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6. 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent and check the clearance on the following valves: a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b. On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8. Valve Arrangement Front to Rear V8-302 Left Bank.................................................................................................................................. ...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank............................................. ..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank...................................................................................................................... .....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank...................................... .......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank................................................................................................................. ............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................ .............................................................................................................................................................. .I-E-I-E-I-E-I-E Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, then translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor constantly monitors air temperature entering the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2507 Intake Air Temperature Sensor: Description and Operation Fig. 2 Air charge temperature (ACT) sensor This sensor, Fig. 2, provides the EFI system with air/fuel mixture temperature information. The air charge temperature sensor is used both as a density corrector to air flow calculation and to proportion the cold enrichment fuel flow. This sensor is similar in construction to the engine coolant temperature sensor and is mounted on an intake manifold runner or on the air cleaner. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 2511 Barometric Pressure Sensor: Locations RH Fender Apron At Wheel Well Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation Fig. 19 Ignition barometric pressure switch. 1984-87 1984---87 This switch, Fig. 19, controls spark timing and/or other electrical devices according to barometric pressure changes. Calibration resistors in the switch assembly cause the ignition module to vary the spark timing. Spark timing is advanced for vehicle operation above a predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some switch assemblies control both spark timing and another device while other switch assemblies control only one or the other. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing Fig. 43 Ignition barometric pressure switch resistance chart. 1985---87 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2525 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2526 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine coolant temperature (ECT) sensor The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2531 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2536 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2537 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2538 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2539 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2540 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2541 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2542 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2543 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2544 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2545 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2546 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2547 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2548 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2549 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2550 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2551 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2552 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2553 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2554 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2555 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2556 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2557 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2558 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2559 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2560 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2561 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2562 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2563 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2564 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2565 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2566 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2567 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2568 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2569 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations EGR Valve Position Sensor: Component Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations > Page 2572 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Engine Control Module: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2577 Engine Control Module: Locations Under right side of instrument panel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2580 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2581 Fig. 133 EEC-IV connector terminal identification. V8-302 & 351 FBC E Series Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2582 Engine Control Module: Description and Operation Fig. 6 Electronic control assembly The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration assembly, Fig. 6. The processor receives input signals from the various sensors. The information obtained is used by the processor to activate engine control systems to obtain optimum emission control and performance. The calibration assembly is a permanent memory device that contains information. The processor applies the sensor inputs to the stored information to determine when and how long the various control systems should be applied. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Locations > Component Locations Feedback Control Solenoid: Component Locations LH Side Of V8-302/5. At Carburetor Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Locations > Component Locations > Page 2587 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2596 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2597 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2598 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2599 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2600 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2601 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2602 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2603 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2604 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2605 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2606 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2607 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2608 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2609 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2610 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2611 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2612 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2618 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2619 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2620 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2621 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2622 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2623 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2624 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2625 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2626 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2627 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2628 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2629 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2630 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2631 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2632 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2633 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2634 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Idle Speed/Throttle Actuator - Electronic: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Idle Speed/Throttle Actuator - Electronic: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Page 2644 IDLE SPEED CONTROL - FI ENGINES W/ISC. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Page 2645 Idle Speed/Throttle Actuator - Electronic: Locations Attached To Carburetor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > DC Motor Idle Speed Control Actuator Idle Speed/Throttle Actuator - Electronic: Description and Operation DC Motor Idle Speed Control Actuator Fig. 5 DC motor idle speed control actuator Control Actuator The DC motor idle speed control actuator (DC-ISCA), Fig. 5, is mounted to the fuel charging assembly and controls the idle speed including, high cam RPM, anti-diesel shut-off, dashpot and pre-positioning for the next engine start. The DC-ISCA is controlled by the EEC-IV system and includes an integral idle tracking switch (ITS). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > DC Motor Idle Speed Control Actuator > Page 2648 Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control (IAC) Valve Fig. 1 Air bypass valve assembly The air bypass valve solenoid, Fig. 1, is used to control engine idle speed and is operated by the EEC-IV control module. This valve allows air to pass around the throttle plates to control, cold engine fast idle, no touch start, dashpot, over temperature idle boost and engine idle load correction. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 2649 Idle Speed/Throttle Actuator - Electronic: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect air bypass valve electrical connector. 3. On models with 4-140 engine, remove air cleaner assembly. 4. On all models, remove air bypass valve attaching bolts, then the air bypass valve and gasket. 5. Reverse procedure to install. Torque air bypass valve attaching bolts to 71 - 102 inch lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 2655 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2662 Main Relay (Computer/Fuel System): Description and Operation Fig. 12 EEC relay type, system application & relay locations EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine applications. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Fig. 1 Jumper wire connections for resetting Check Engine Lamp. 1985-90 Models w/EEC-IV This lamp will be illuminated when the ignition switch is placed in the On position. After engine is started the lamp should go off, unless a problem has been detected by the EEC-IV system. After diagnosis and repair, the Check Engine/MIL lamp will automatically reset when stored codes are cleared from the EEC-IV system memory. After diagnosis and repair, EEC-IV memory may be cleared of stored codes as follows: 1. With ignition switch in the Off position, connect a jumper wire between Self Test and Self Test Input (STI) connectors, Fig. 1. On Aerostar, the Self Test and STI connectors are gray in color and are located on lefthand fender apron, near the Electronic Engine Control (EEC) relay. On Bronco and F Series, the Self Test and STI connectors are located in the area of the EEC system charcoal canister. On Bronco II and Ranger, the Self Test connector and STI connector are red in color and they are both located on the righthand fender apron near the Electronic Engine Control (EEC) relay. On E Series, the Self Test and the STI connectors are located on the righthand fender apron in the area of the MAP sensor and starter motor relay. 2. Position ignition switch in On position, then disconnect jumper wire from test connector terminals. Disconnect jumper as soon as Check Engine lamp starts flashing. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Manifold Pressure/Vacuum Sensor: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service > Page 2670 Manifold Pressure/Vacuum Sensor: Technical Service Bulletins EEC IV MAP Sensor - New Part Numbers/Applications Article No. 85-12-17 MAP SENSOR - EEC IV - NEW PART NUMBERS/APPLICATIONS FORD 1984-85 MUSTANG, LTD, TEMPO, THUNDERBIRD, CROWN VICTORIA LINCOLN-MERCURY 1984-85 CAPRI, MARQUIS, TOPAZ, COUGAR, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN LIGHT TRUCK 1984-85 RANGER, BRONCO II, E150/250, F150/250, BRONCO New MAP sensor part numbers have recently been released. The MAP sensor formerly referred to as the Yellow Dot MAP is now identified with part number E43Z-9F479-B. The Yellow Dot is no longer used for identification. The MAP sensor used for 3.8L CFI-SD applications will be identified as E5SZ-9F479-A. The chart lists the correct MAP sensor to the correct EEC IV application. PART NUMBER PART NAME CLASS E5SZ-9F479-A MAP Sensor C E43Z-9F479-B MAP Sensor A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 2671 MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 2672 Manifold Pressure/Vacuum Sensor: Locations On right front fender well. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2677 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2678 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2679 Oxygen Sensor: Description and Operation Fig. 8 Exhaust gas oxygen (EGO) sensor The exhaust gas oxygen sensor supplies the ECA with a signal which indicates either a rich or lean condition during engine operation. The sensor is threaded into the center of the exhaust manifold on 4-140 and 6-300 engines, threaded into the rear of left and right exhaust manifold assemblies on V6-171 engine or threaded into the rear right exhaust manifold assembly on V8-302 and 351 engine, Fig. 8. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Power Steering Pressure Switch: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Engine Control Module: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2689 Engine Control Module: Locations Under right side of instrument panel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2692 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2693 Fig. 133 EEC-IV connector terminal identification. V8-302 & 351 FBC E Series Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2694 Engine Control Module: Description and Operation Fig. 6 Electronic control assembly The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration assembly, Fig. 6. The processor receives input signals from the various sensors. The information obtained is used by the processor to activate engine control systems to obtain optimum emission control and performance. The calibration assembly is a permanent memory device that contains information. The processor applies the sensor inputs to the stored information to determine when and how long the various control systems should be applied. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 2698 Main Relay (Computer/Fuel System): Description and Operation Fig. 12 EEC relay type, system application & relay locations EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine applications. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, then translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor constantly monitors air temperature entering the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 2706 Barometric Pressure Sensor: Locations RH Fender Apron At Wheel Well Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation Fig. 19 Ignition barometric pressure switch. 1984-87 1984---87 This switch, Fig. 19, controls spark timing and/or other electrical devices according to barometric pressure changes. Calibration resistors in the switch assembly cause the ignition module to vary the spark timing. Spark timing is advanced for vehicle operation above a predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some switch assemblies control both spark timing and another device while other switch assemblies control only one or the other. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing Fig. 43 Ignition barometric pressure switch resistance chart. 1985---87 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 2720 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 2721 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 7 Engine coolant temperature (ECT) sensor The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2726 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2731 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2732 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2733 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2734 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2735 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2736 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2737 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2738 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2739 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2740 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2741 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2742 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2743 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2744 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2745 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2746 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2747 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2748 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2749 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2750 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2751 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2752 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2753 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2754 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2755 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2756 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2757 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2758 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2759 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2760 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2761 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2762 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2763 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2764 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations EGR Valve Position Sensor: Component Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations > Page 2767 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2771 Intake Air Temperature Sensor: Description and Operation Fig. 2 Air charge temperature (ACT) sensor This sensor, Fig. 2, provides the EFI system with air/fuel mixture temperature information. The air charge temperature sensor is used both as a density corrector to air flow calculation and to proportion the cold enrichment fuel flow. This sensor is similar in construction to the engine coolant temperature sensor and is mounted on an intake manifold runner or on the air cleaner. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Manifold Pressure/Vacuum Sensor: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service > Page 2779 Manifold Pressure/Vacuum Sensor: Technical Service Bulletins EEC IV MAP Sensor - New Part Numbers/Applications Article No. 85-12-17 MAP SENSOR - EEC IV - NEW PART NUMBERS/APPLICATIONS FORD 1984-85 MUSTANG, LTD, TEMPO, THUNDERBIRD, CROWN VICTORIA LINCOLN-MERCURY 1984-85 CAPRI, MARQUIS, TOPAZ, COUGAR, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN LIGHT TRUCK 1984-85 RANGER, BRONCO II, E150/250, F150/250, BRONCO New MAP sensor part numbers have recently been released. The MAP sensor formerly referred to as the Yellow Dot MAP is now identified with part number E43Z-9F479-B. The Yellow Dot is no longer used for identification. The MAP sensor used for 3.8L CFI-SD applications will be identified as E5SZ-9F479-A. The chart lists the correct MAP sensor to the correct EEC IV application. PART NUMBER PART NAME CLASS E5SZ-9F479-A MAP Sensor C E43Z-9F479-B MAP Sensor A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 2780 MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 2781 Manifold Pressure/Vacuum Sensor: Locations On right front fender well. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2786 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2787 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2788 Oxygen Sensor: Description and Operation Fig. 8 Exhaust gas oxygen (EGO) sensor The exhaust gas oxygen sensor supplies the ECA with a signal which indicates either a rich or lean condition during engine operation. The sensor is threaded into the center of the exhaust manifold on 4-140 and 6-300 engines, threaded into the rear of left and right exhaust manifold assemblies on V6-171 engine or threaded into the rear right exhaust manifold assembly on V8-302 and 351 engine, Fig. 8. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Power Steering Pressure Switch: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Full Close Switch > Component Information > Description and Operation Throttle Full Close Switch: Description and Operation The idle tracking switch, is a mechanically operated electric switch held open by the throttle linkage when the throttle is closed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2800 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2801 OASIS CODES: 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2802 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2803 THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2804 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box > Page 2807 Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > Page 2808 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect throttle position sensor electrical connector. 3. Scribe a reference mark across edge of sensor and to throttle body to ensure correct position during installation. 4. Remove two sensor attaching screws, then the sensor and gasket. 5. Reverse procedure to install, noting the following: a. Slide the throttle position sensor rotary tangs into position over throttle shaft blade, then rotate sensor clockwise to align scribe marks. b. Torque sensor attaching screws to 11 - 16 inch lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vacuum Switch > Component Information > Locations Vacuum Switch: Locations RH Fender Apron At Wheel Well Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications VEHICLE SPEED SENSOR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2815 Vehicle Speed Sensor: Locations At LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 2818 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Full Close Switch > Component Information > Description and Operation Throttle Full Close Switch: Description and Operation The idle tracking switch, is a mechanically operated electric switch held open by the throttle linkage when the throttle is closed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2826 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2827 OASIS CODES: 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 2828 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2829 THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2830 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box > Page 2833 Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > Page 2834 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect throttle position sensor electrical connector. 3. Scribe a reference mark across edge of sensor and to throttle body to ensure correct position during installation. 4. Remove two sensor attaching screws, then the sensor and gasket. 5. Reverse procedure to install, noting the following: a. Slide the throttle position sensor rotary tangs into position over throttle shaft blade, then rotate sensor clockwise to align scribe marks. b. Torque sensor attaching screws to 11 - 16 inch lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vacuum Switch > Component Information > Locations Vacuum Switch: Locations RH Fender Apron At Wheel Well Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications VEHICLE SPEED SENSOR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2841 Vehicle Speed Sensor: Locations At LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Control/Speedometer Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 2844 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Vacuum Control Solenoid Valve > Component Information > Locations Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Vacuum Control Solenoid Valve > Component Information > Locations > Page 2850 Air Injection Vacuum Control Solenoid Valve: Description and Operation Solenoid Valve The dual thermactor air control solenoid valve assembly consists of two normally closed solenoid vacuum valves (TAB and TAD), one controlling the thermactor air bypass valve and the other controlling thermactor diverter valve. Both are vented when de-energized and is sourced by the intake manifold vacuum reservoir and controlled by the EEC-IV system. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid > Component Information > Locations Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Air Bypass Valves Air Diverter Valve: Description and Operation Air Bypass Valves Fig. 64 Normally closed air bypass valves Fig. 65 Normally open air bypass valves with vacuum vents Fig. 66 Normally open air bypass valves without vacuum vent There are two general groups of bypass valves, normally open and normally closed. Both groups are available in both remote and pump-mounted versions. Normally closed valves, Fig. 64, supply air to the exhaust system with medium and high applied vacuum signals during normal modes (engine operating at normal operating temperature), short idles, and some accelerations. With low or no vacuum applied to pump, air is dumped through silencer ports of valve. Normally open valves with a vacuum vent, Fig. 65, provide a timed air dump during decelerations and also dump when a vacuum pressure difference is maintained between the signal port and the vent port. The signal port must have 3 inches Hg more vacuum than the vent port to hold the dump. This mode is used to protect the catalyst from overheating. Normally open valves without a vacuum vent, Fig. 66, provide a timed dump of air for 1.1 or 2.8 seconds when a sudden high vacuum of about 20 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Air Bypass Valves > Page 2858 inches Hg is applied to the signal port. This prevents backfire during deceleration. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Air Bypass Valves > Page 2859 Air Diverter Valve: Description and Operation Air Divert/Control Valves Fig. 67 Standard air control valve. 1983---87 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. 1984---87 vehicles use the standard air control valve, Fig. 67. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Testing and Inspection 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Description and Operation > Air Check Valve Air Injection Check Valve: Description and Operation Air Check Valve 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Description and Operation > Air Check Valve > Page 2867 Air Injection Check Valve: Description and Operation Anti-Backfire Gulp Valve Fig. 73 Anti-backfire gulp valve The anti-backfire gulp valve, used on some vehicles, routes a portion of thermactor air to the intake manifold and is activated by intake manifold vacuum signal, Fig. 73. This valve is located downstream from the air bypass valve and functions only during periods of sudden decrease in manifold pressure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Testing and Inspection > Anti-Backfire Gulp Valve Air Injection Check Valve: Testing and Inspection Anti-Backfire Gulp Valve 1. Disconnect supply hose from air pump side of valve. 2. Observe valve pintle by looking into valve through disconnected port. 3. Accelerate engine to 3000 RPM, then release throttle. Pintle should be open and then close. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Testing and Inspection > Anti-Backfire Gulp Valve > Page 2870 Air Injection Check Valve: Testing and Inspection Check Valves 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Combination Air Bypass/Air Control Valves 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Combination Air Bypass/Air Control Valves > Page 2875 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Combination Air Bypass/Air Control Valves > Page 2876 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 of Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Combination Air Bypass/Air Control Valves > Page 2877 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Combination Air Bypass/Air Control Valves > Page 2878 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve > Page 2881 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve > Page 2882 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve > Page 2883 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Hose/Tube > Component Information > Testing and Inspection Air Injection Hose/Tube: Testing and Inspection 1. Inspect all hoses and tubes for deterioration or cracks. 2. Check hose and tube routing as interference may cause wear. 3. Check all hose and tube connections. 4. Check the pressure side of the system for leaks with a soapy water solution. With the pump running, bubbles will form if a leak exists. 5. When replacing any hose or tube, note routing before removal. The hoses used with this system are made of special material to withstand high temperature. No other type should be used. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Testing and Inspection Air Pump: Testing and Inspection 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 and 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 by-pass valve from pump. 4. Install suitable thermactor test gauge in end of hose disconnected from by-pass valve. Secure hose with clamp to prevent it from blowing out. On side or cover mounted by-pass valves, install an elbow and hose adapter, then install test gauge. 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 2.25 psi. If thermactor test gauge 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 2.25 psi, or if air flow is not heard and felt, replace pump and repeat test. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve, Air Injection > Component Information > Description and Operation > Temperature Vacuum Switch (TVS) Thermal Vacuum Valve: Description and Operation Temperature Vacuum Switch (TVS) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve, Air Injection > Component Information > Description and Operation > Temperature Vacuum Switch (TVS) > Page 2897 Thermal Vacuum Valve: Description and Operation Thermactor Idle Vacuum Valve (TIV) Fig. 74 Typical Thermactor idle vacuum valve schematic Fig. 75 Thermactor idle vacuum valve (TIV) This valve, Fig. 74, used on some vehicles, operates in conjunction with a vacuum delay valve and provides backfire control, full time idle air dump, cold temperature catalyst protection and cold EGR lockout. This valve prevents excessive underbody temperature caused by the exhaust system by diverting secondary air pump output during extended engine idle. EGR port vacuum at the carburetor moves the power diaphragm which opens or closes vents to the atmosphere by moving the valve membrane, Fig. 75. Vacuum at the EGR port switches off the thermactor at idle due to the lack of vacuum at closed throttle conditions. The idle vacuum valve is open and dumps thermactor air to the atmosphere during cold engine operation, extended idle periods and deceleration. When the engine has reached normal operating temperature, the vacuum valve is closed to the atmosphere to allow passage of thermactor air. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Description and Operation Vacuum Check Valve: Description and Operation 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Description and Operation > Page 2901 Vacuum Check Valve: Testing and Inspection 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter > Page 2906 Catalytic Converter: Description and Operation General Description Fig. 4 Single type catalytic converter with single substrate catalyst Fig. 5 Single type catalytic converter with dual substrate catalyst Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter > Page 2907 Fig. 6 Dual type catalytic converter The catalytic converter used on some vehicles, serves two purposes: it permits a faster chemical reaction to take place and although it enters into the chemical reaction, it remains unchanged, ready to repeat the process. The catalytic converter combines hydrocarbons (HC) and carbon monoxide (CO) with oxygen to form water (H2O) and carbon dioxide (CO2). The catalyst is structured in the form of a honeycomb monolithic composition, Figs. 4,5 and 6 . The catalyst consists of a porous substrate of an inert material, coated with platinum and other noble metals (the catalytically active materials.) This device, located in the exhaust system between the exhaust manifold and muffler, requires the use of heat shields, in some cases, due to its high operating temperatures. The heat shields are necessary to protect chassis components, passenger compartment and other areas from heat related damage. A small diameter fuel tank filler tube neck is incorporated to prevent the larger service station pump nozzle, used for leaded fuels, being inserted into the filler tube, thereby preventing system contamination. Since the use of leaded fuels contaminates the catalysts, deteriorating its effectiveness, the use of unleaded fuels is mandatory in vehicles equipped with catalytic converters. The catalytic converter can tolerate small amounts of leaded fuels without permanently reducing the catalyst effectiveness. There are basically three types of catalysts, the conventional oxidation catalyst (COC) containing Platinum (Pt) and Palladium (Pd) which are effective for catalyzing the oxidation reactions of hydrocarbons (HC) and carbon monoxide (CO) emissions. A three-way catalyst (TWC) containing Platinum (Pt) and Rhodium (RH), is not only effective for catalyzing the oxidation reactions of HC and CO emissions, but it also catalyzes the reduction of nitrogen oxides (NOx). A light off catalyst (LOC) is a single bed converter. It is arranged in series with the main catalytic converter assembly of COC and/or TWC as the aft member(s). This converter is designed to perform the very specialized function of exhaust emission control during engine warm-up when the main converter(s) is not yet at the temperature required for maximum efficiency. The LOC is designed to operate effectively in the high environmental conditions that exist near the manifold flange. The LOC is designed with a minimum heat sink effect and, provides minimum delay in warm-up of the main catalytic converter(s). The oxidation catalyst requires the use of a secondary air source which is provided by the pulse air or thermactor air injection systems. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2908 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 2909 Catalyst and Exhaust Systems Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Specifications > Mechanical Specifications > Page 2915 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Specifications > Page 2916 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: Customer Interest Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 2926 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: All Technical Service Bulletins Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions Maintenance Light Stays ON > Page 2932 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Solenoid > Component Information > Locations Bowl Vent Solenoid: Locations At RH Side Of Carburetor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Solenoid > Component Information > Locations > Page 2937 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Solenoid > Component Information > Locations > Page 2938 Bowl Vent Solenoid: Testing and Inspection 1. Apply 12 volts to valve and ensure valve closes to block air passage. 2. Replace valve if it does not close when energized. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Carburetor Fuel Bowl Thermal Vent Valve Bowl Vent Valve: Description and Operation Carburetor Fuel Bowl Thermal Vent Valve 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Carburetor Fuel Bowl Thermal Vent Valve > Page 2943 Bowl Vent Valve: Description and Operation Solenoid Vent Valve Fig. 57 Solenoid vent valve The purpose of this valve, Fig. 57, is to close off the fuel bowl vent line when the engine is operating. It is a normally open valve located in the fuel bowl vent to canister line. This valve is on carburetors which do not have a built-in fuel bowl vent valve. When the ignition switch is turned on, the coil energizes and the plunger is pulled against the valve seat to the closed position to prevent purge vacuum from reaching the carburetor fuel bowl and upsetting the balanced air pressure. When the ignition switch is turned off, the coil de-energizes and spring pressure unseats the plunger to allow fuel vapors to flow to the carbon canister where they are stored until purged when the engine is started. If vacuum from the purge control valve does reach the fuel bowl vent line, the resultant low air pressure in the bowl will cause a lean fuel mixture condition. When diagnosing a driveability problem associated with a lean fuel mixture, check the solenoid vent valve and/or the built-in fuel bowl vent. The vent valves must be closed when the engine is operating. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Carburetor Fuel Bowl Thermal Vent Valve > Page 2944 Bowl Vent Valve: Description and Operation Vacuum Bowl Vent Valve Fig. 60 Vacuum bowl vent valve This valve, Fig. 60, used on some vehicles, is a vacuum operated on/off valve. This valve controls vapor flow from the carburetor bowl to the carbon canister. When the engine is running, manifold vacuum closes the flow path from the carburetor bowl to the carbon canister. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Testing and Inspection > Solenoid Vent Valve Bowl Vent Valve: Testing and Inspection Solenoid Vent Valve Apply 9---14 volts DC to valve. If valve does not close, replace valve. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Testing and Inspection > Solenoid Vent Valve > Page 2947 Bowl Vent Valve: Testing and Inspection Thermal Vent Valve 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Testing and Inspection > Solenoid Vent Valve > Page 2948 Bowl Vent Valve: Testing and Inspection Vacuum Bowl Vent Valve 1. Ensure that air flows between carburetor port and canister port when no vacuum is applied to vacuum signal nipple. 2. Apply vacuum to vacuum signal nipple and ensure that air does not flow between carburetor port and canister port. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Testing and Inspection > Solenoid Vent Valve > Page 2949 Bowl Vent Valve: Testing and Inspection Vacuum/Thermostatic Bowl Vent Valve 1. With valve temperature at or above 120°F, ensure that air flows between carburetor port and canister port when no vacuum is applied to vacuum signal nipple. 2. With valve temperature at or above 120°F, apply vacuum to vacuum signal nipple and ensure that air does not flow between carburetor port and canister port. 3. With valve temperature at or below 90°F, ensure that there is no or very little air flow between carburetor port and canister port, whether or not vacuum is applied to vacuum signal nipple. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > Canister Purge Regulator Valve Canister Purge Control Valve: Description and Operation Canister Purge Regulator Valve Fig. 56 Purge control valves CANISTER MOUNTED PURGE CONTROL VALVE The valve, Fig. 56, 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. 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. IN-LINE MOUNTED PURGE CONTROL VALVE The valve, Fig. 56, is installed in line with 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. 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > Canister Purge Regulator Valve > Page 2954 Canister Purge Control Valve: Description and Operation PVS Valve The PVS (ported vacuum switch) valve allows vacuum to open the purge control valve as the engine warms up. The purge control valve closes as soon as the engine is turned off and vacuum drops off. The evaporative emission system may be equipped with either a 2 or 4 port PVS. The 4 port PVS valve is actually two vacuum valves in one, and performs the same function as two 2 port valves. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > Page 2955 Canister Purge Control Valve: Testing and Inspection Fig. 56 Purge control valves 1. Apply vacuum to port B, Fig. 56. If there is vacuum flow, replace valve. 2. Apply and maintain 16 inches Hg vacuum to port A, then apply vacuum to port B. If air does not flow, replace valve. Never apply vacuum to port(s) C. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2959 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Description and Operation 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Description and Operation > Page 2963 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Description and Operation > Page 2964 Charcoal Canister: Testing and Inspection There are no moving parts or nothing to wear in the canister. Check for loose, missing, cracked, or broken connections and parts. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Fuel Overflow Reservoir > Component Information > Description and Operation Fuel Overflow Reservoir: Description and Operation This system provides a vapor space above the gasoline surface in the fuel tank. This area is enough to permit breathing space for the tank vapor valve assembly under all static and most dynamic conditions. Horizontally mounted tanks accomplish this by a raised mounting section for the valve assembly which is centrally located on the upper surface of the tank. Vertically mounted tanks use a centrally mounted vapor valve assembly on the uppermost surface of the fuel tank. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Description and Operation Liquid Vapor Separator: Description and Operation Fig. 47 Fuel tank vapor valve All fuel tank vapor valves, Fig. 55, use a small orifice which allows only vapor and not fuel to pass into the line going to the vapor storage canister. This assembly is mounted on the fuel tank. Fuel vapors trapped in the sealed fuel tank are vented through the vapor valve assembly. The vapors leave the valve assembly through a single vapor line and continue to the charcoal canister for storage, until they are purged into the engine. On vehicles equipped with fuel/vapor return lines, vapors created in the fuel line is continuously vented back to the fuel tank. This prevents engine surging from fuel enrichment. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Description and Operation > Page 2974 Thermal Vacuum Valve - EVAP: Testing and Inspection Fig. 22 Ported vacuum switches & vacuum control valves Fig. 23 Electrical vacuum switch VACUUM SWITCH TEST 1. With engine cold, turn ignition key to ``ON,'' connect vacuum gauge to port A, Figs. 22 and 23, and a vacuum source to port B and then C. There should be no vacuum flow from A to B but there should be vacuum from A to C. 2. Start engine and run until it reaches normal operating temperature, then apply vacuum to port B and then port C. There should be vacuum from A to B but no vacuum from A to C. On 4-port valve, check A1 to B1 and A2 to B2 separately. 3. If vacuum flow is not as described, replace valve. ELECTRICAL SWITCH TEST 1. Using a suitable ohmmeter, measure resistance across switch terminals with engine cold and note reading. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Description and Operation > Page 2975 2. Start engine and allow to reach operating temperature, then measure resistance across switch terminals. 3. A change in resistance should be noted at cold and warm engine temperature readings. 4. Check vacuum portion of switch as described above. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Description and Operation Vacuum Delay Valve: Description and Operation 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Ported Vacuum Valves Vacuum Delay Valve: Testing and Inspection Ported Vacuum Valves Fig. 22 Ported vacuum switches & vacuum control valves 1. With engine cold, ensure that passage A to B is closed, and passage A to C is open, Fig. 22. 2. Start engine and run until it reaches normal operating temperature, then ensure that passage A to B is open and passage A to C is closed. On 4-port valve, check A1 to B1 and A2 to B2 separately. 3. If valve does not operate as described, replace valve. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Ported Vacuum Valves > Page 2981 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Module > Component Information > Locations EGR Control Module: Locations Behind LH Side Of Instrument Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations EGR Control Solenoid: Component Locations LH Side Of 6-300/4. Top Rear Of Engine Applicable to: 9L Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations > Page 2992 EGR Control Solenoid: Connector Locations Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations > Page 2993 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 2994 EGR Control Solenoid: Description and Operation The dual EGR solenoid valve assembly consists of two dithering solenoid valves. The first is a vacuum valve which supplies vacuum to the sonic EGR valve when energized. The second is a vent valve which vents the EGR valve to the atmosphere when de-energized. Both solenoid valves receive variable duty cycle signals from the ECA according to EGR requirements. A restrictor is added in the vacuum valve inlet port to reduce its flow compared to that of the vent valve so that when vacuum valve sticks open, the vent valve can immediately vent the vacuum valve flow without affecting the devices being controlled. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Locations > EGR Vacuum Switch EGR Vacuum Regulator Solenoid: Locations EGR Vacuum Switch Attached To Bracket On LH Valve Cover Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Locations > EGR Vacuum Switch > Page 3001 EGR Vacuum Regulator Solenoid: Locations EGR Vent Solenoid LH Side Of V8-302/5. Attached to LH Valve Cover Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Maintenance Light > Component Information > Locations EGR Maintenance Light: Locations On Dash Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3008 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3009 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. Fig. 6 EGR valve position sensor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3010 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 3011 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. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > EGR Valve Tests, 1983-85 EGR Valve: Testing and Inspection EGR Valve Tests, 1983-85 PORTED TYPE EGR VALVE Signal Response Test 1. Check all system vacuum lines for proper routing and secure connections. 2. Inspect vacuum lines for wear or damage and replace as necessary. 3. Ensure that there is no vacuum to valve at idle with engine at normal operating temperature. Recheck hose routing if vacuum is present. 4. Ensure that there is vacuum to valve at 3000 RPM on 4-140 engine, or kickdown RPM on other engines, with engine at operating temperature. If there is no vacuum, trace system vacuum lines back from EGR valve and replace components as necessary. Refer to vehicle emission decal for kickdown RPM specification. Functional Test 1. Operate engine at idle and apply 8 inches Hg vacuum to valve. Valve stem should move, opening valve, and engine should roughen. 2. If valve stem moves but engine does not roughen, remove valve and clean inlet and outlet ports with wire brush. Do not use sand blasting or gasoline to clean EGR valve. 3. Run engine at idle and trap and hold 4 inches Hg vacuum. 4. If vacuum drops more than 1 inch Hg vacuum in 30 seconds, replace valve. Seat Test This test should be performed when the valve is suspected of leaking, indicated by rough engine operation 1. Install blocking gasket (no flow holes) between mounting and valve, then retighten valve. 2. Improved engine operation indicates a defective valve. Clean or replace as necessary. 3. Replace blocking gasket with conventional gasket. INTEGRAL BACK PRESSURE TRANSDUCER & VALVE & TRANSDUCER TYPE EGR VALVES Signal Response Test 1. Check all system vacuum lines for proper routing and secure connections. 2. Inspect vacuum lines for wear or damage and replace as necessary. 3. Disconnect and plug vacuum line to EGR valve, then connect vacuum pump to valve. 4. Run engine at idle and apply 6 inches Hg vacuum to valve. 5. If vacuum holds and valve opens and stays open, replace valve. 6. Ensure that there is no vacuum to valve at idle. If there is, check hose routing. 7. Ensure that there is no vacuum to valve or valve operation when engine is cold. If there is, check ported vacuum switch and thermal vacuum switch, replacing as necessary. 8. Ensure that there is vacuum to valve at 3000 RPM on 4-140 engine, or kickdown RPM on all other engines, with engine at operating temperature. If there is no vacuum, trace system vacuum lines back from EGR valve and replace components as necessary. Refer to vehicle emission decal for kickdown RPM specification. Functional Test 1. Select drive socket wrench with O. D. of approximately 1/16 inch less than I. D. of tailpipe. 2. Cover drive socket hole and insert socket in tailpipe with open end facing out. Do not block tailpipe fully and do not run engine faster than idle or for prolonged periods of time. Be sure to remove socket from tailpipe at end of test. 3. Run engine at idle and gradually apply vacuum. Valve stem/diaphragm should move smoothly and engine should roughen. 4. Trap 6 inches Hg of vacuum and hold. Vacuum should drop more than 1 inch Hg in 30 seconds. 5. If valve stem/diaphragm moves smoothly but engine does not roughen, clean valve passages. 6. If conditions in steps 3 and/or 4 are not met, replace valve. 7. If valve is suspected of sticking, remove valve from engine and cycle valve by pressing carefully with fingers against lower transducer plate. 8. If valve sticks open when fingers are released, replace valve. 9. If valve does not stick, clean inlet and outlet ports with wire brush. Do not use sand blasting or gasoline to clean the valve. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > EGR Valve Tests, 1983-85 > Page 3014 EGR Valve: Testing and Inspection EGR Venturi Vacuum Amplifier Idle must be set to specifications, engine must be at normal operating temperature and manifold vacuum must be adequate for this test. 1. Connect a vacuum gauge hose at EGR valve. The gauge may read as high as 2 inches Hg at idle. 2. Disconnect venturi hose at carburetor and increase engine speed to 2000 RPM (3000 on 2300 cc engines). 3. Connect venturi hose. Gauge should read 4 inches Hg. 4. Return engine to idle. Gauge should return to initial reading. 5. If operation is not as described previously, replace VVA. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3019 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3020 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3021 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3022 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3023 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3024 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3025 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3026 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3027 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3028 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3029 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3030 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3031 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3032 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3033 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3034 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3035 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3036 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3037 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3038 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3039 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3040 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3041 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3042 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3043 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3044 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3045 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3046 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3047 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3048 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3049 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3050 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3051 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3052 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Locations > Component Locations EGR Valve Position Sensor: Component Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Locations > Component Locations > Page 3055 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Description and Operation > Page 3059 Thermal Vacuum Valve: Testing and Inspection Fig. 22 Ported vacuum switches & vacuum control valves Fig. 23 Electrical vacuum switch VACUUM SWITCH TEST 1. With engine cold, turn ignition key to ``ON,'' connect vacuum gauge to port A, Figs. 22 and 23, and a vacuum source to port B and then C. There should be no vacuum flow from A to B but there should be vacuum from A to C. 2. Start engine and run until it reaches normal operating temperature, then apply vacuum to port B and then port C. There should be vacuum from A to B but no vacuum from A to C. On 4-port valve, check A1 to B1 and A2 to B2 separately. 3. If vacuum flow is not as described, replace valve. ELECTRICAL SWITCH TEST 1. Using a suitable ohmmeter, measure resistance across switch terminals with engine cold and note reading. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Description and Operation > Page 3060 2. Start engine and allow to reach operating temperature, then measure resistance across switch terminals. 3. A change in resistance should be noted at cold and warm engine temperature readings. 4. Check vacuum portion of switch as described above. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 3064 Positive Crankcase Ventilation: 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > EGR Control Module > Component Information > Locations EGR Control Module: Locations Behind LH Side Of Instrument Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3074 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3075 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3076 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3077 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3078 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3079 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3080 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3081 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3082 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3083 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3084 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3085 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3086 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3087 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3088 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3089 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3090 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3091 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3092 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3093 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3094 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3095 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3096 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3097 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3098 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3099 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3100 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3101 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3102 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3103 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3104 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3105 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3106 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3107 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations EGR Valve Position Sensor: Component Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations > Component Locations > Page 3110 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: Customer Interest Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions Maintenance Light Stays ON > Page 3119 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: All Technical Service Bulletins Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 3125 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 Thermostatic Air Cleaner Vacuum Switch: Description and Operation Fig. 1 Bi-metal switch AIR TEMPERATURE CONTROL SENSOR A vacuum operated duct valve with a thermostatic bi-metal switch, Fig. 1, is used. The valve in the duct assembly is in an open position when the engine is not operating. When the engine is operating at below 75° F, manifold vacuum is routed through the bi-metal switch to the vacuum motor to close the duct valve allowing only heated air to enter the air cleaner. When the engine reaches normal operating temperature, the bi-metal switch opens an air bleed which eliminates the vacuum and the duct valve opens, allowing only cold air to enter the air cleaner. During periods of acceleration the duct valve will open regardless of temperature due to the loss of manifold vacuum. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 3130 Fig. 2 Cold weather modulator COLD WEATHER MODULATOR This modulator, Fig. 2, is used on some models to prevent the air cleaner door from opening when outside air is below a predetermined temperature. At higher ambient temperatures, the modulator is inoperative. During acceleration, with outside air below the preset temperature, the modulator will close off vacuum to the motor and hold the duct open. The modulator is located in-line between the air temperature control sensor and the vacuum duct motor. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 3131 Thermostatic Air Cleaner Vacuum Switch: Testing and Inspection AIR CLEANER TEMPERATURE SENSOR 1. With ambient temperature less than 75° F and engine cold, remove components necessary to observe position of duct door. 2. Start engine and ensure that duct door is in full heat position. 3. Allow engine to warm up, ensuring that door begins to open for fresh air at specified temperature for particular sensor. Brown sensor should begin to bleed off vacuum at approximately 75° F, black, clear or pink sensor at approximately 90° F, and blue, green, or yellow sensor at approximately 105° F. 4. Install components removed in step 1. Fig. 3 Cold weather modulator operating chart COLD WEATHER MODULATOR 1. Apply 16 inches Hg vacuum to motor side of modulator. 2. Ensure that vacuum holds or leaks according to ambient temperature and temperature sensor color, Fig. 3. VACUUM MOTOR Apply vacuum to vacuum motor and ensure that door stem pulls up and stays up until vacuum source is eliminated. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vacuum Restrictor > Component Information > Description and Operation Vacuum Restrictor: Description and Operation Fig. 38 Vacuum restrictor The orifice type flow restrictor, Fig. 38, 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Carburetor Fuel Pressure: Specifications Carburetor 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Carburetor > Page 3140 Fuel Pressure: Specifications Fuel Injection FUEL SYSTEM SPECIFICATIONS Pressure Key On Engine Off ............................................................................................................................... ................................................... 35-45 psi Engine Idling .................................................................... ....................................................................................................................... 28-38 psi Volume A minimum of 170 ml (5.6 oz) in 10 seconds. WARNING: Fuel supply lines will remain pressurized for some period of time after the engine is shut off. Before opening the fuel system, relieve the fuel pressure. FUEL PRESSURE RELIEF PROCEDURE - Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch, or the in-line high pressure fuel pump. - Crank engine for about ten seconds. NOTE: Engine may start and run for a short time. If so, crank engine an additional five seconds after engine stalls. - Reconnect the electrical connector that was disconnected in the first step. - Disconnect negative battery cable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3141 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: FUEL SUPPLY LINES ON EFI ENGINES WILL REMAIN PRESSURIZED FOR SOME PERIOD OF TIME AFTER THE ENGINE IS SHUT OFF. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. FUEL SYSTEM PRESSURE RELIEF - EFI ENGINES Before opening the fuel system on vehicles with EFI engines, relieve fuel pressure as follows: 1. Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch or the in-line high pressure fuel pump. 2. Crank engine for approximately ten seconds. Note: Engine may start and run for a short time. If so, crank engine an additional 5 seconds after engine stalls. 3. Re-connect the electrical connector that was disconnected in step 1 and disconnect battery ground cable. Alternative Method Some EFI vehicles have a port (fitting) on the fuel rail used for measuring fuel pressure. If so equipped, use the following method: Install fuel pressure relief tool No. T80L-9974-B or equivalent to measuring port on engine fuel rail. - Position drain hose in suitable container, then depress relief button. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3153 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3154 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3155 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3156 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3157 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3158 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3159 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3160 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3161 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3162 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3163 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3164 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3165 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3166 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3167 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3168 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3169 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3175 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3176 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3177 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3178 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3179 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3180 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3181 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3182 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3183 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3184 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3185 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3186 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3187 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3188 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3189 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3190 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3191 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3192 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3193 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3194 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3195 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3196 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3197 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3198 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3199 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3200 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3201 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3202 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3203 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3204 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3205 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3206 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3207 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3208 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3209 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3210 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3211 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3212 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3213 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3214 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3215 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3216 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3217 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3218 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3219 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3220 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3221 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3222 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3223 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3224 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3225 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3226 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Page 3227 FUEL INJECTED MODEL SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). Set parking brake and block wheels. - Bring engine to normal operating temperature (upper radiator hose hot). - Disconnect the electric connector on the evaporative cannister purge solenoid. - Disconnect and plug the vacuum hose to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission in "DRIVE" position. - Loosen the Throttle Solenoid Positioner (TSP) dashpot mounting bracket hold-down screw. - 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. - Retighten the TSP dashpot mounting bracket hold-down screw. - Remove the plug from the vacuum hose to the VOTM kicker and reconnect. - Reconnect the electric connector on the evaporative cannister purge solenoid. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 3230 Idle Speed: Adjustments Fast Idle Speed FAST IDLE SPEED ADJUSTMENT - Place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the electric connector on the evaporative cannister purge solenoid. - Disconnect the vacuum hose at the EGR valve and plug. - Place the fast idle adjustment mechanism on specified step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove the plug from the EGR vacuum hose and reconnect. Reconnect the electric connector on the evaporative cannister purge solenoid. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments Fig. 1 Propane enrichment specifications Refer to Propane Enrichment Chart, Fig. 1, when adjusting. 1. Apply parking brake, block wheels, disconnect automatic brake release, if equipped, and plug vacuum connection. 2. Connect suitable tachometer to engine. 3. If vehicle is equipped with hot idle compensator (HIC), ensure HIC is in closed position and remains closed throughout test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to ensure HIC is closed. 4. On 1983 models except V8-302 engine with 2150A-2V feedback carburetor, proceed as follows: a. Disconnect fuel evaporative purge return hose, if equipped, and plug connection. b. Disconnect fuel evaporative purge hose, if equipped, at air cleaner and plug nipple. 5. On all vehicles, disconnect flexible fresh air tube from air cleaner duct or adapter, then, using tool T75L-9600-A or equivalent, insert tool hose approximately 3/4 of the way into duct or fresh air tube. Secure hose with tape as necessary. 6. On vehicles equipped with thermactor systems, revise dump valve vacuum hoses as follows: a. On dump valves with two vacuum fittings, disconnect and plug hoses. b. On dump valves with one fitting or combination air bypass/air control valve, except vehicles with feedback carburetor, remove hose at dump valve and plug hose. Connect slave hose from dump valve vacuum fitting to an intake manifold vacuum fitting. c. On V8-351 engine equipped with 4180C-4V carburetor, disconnect and plug vacuum hose to dump valve. 7. On 1984 - 85 models with feedback carburetor, disconnect battery ground cable for at least 10 seconds. 8. On all models with feedback carburetor, proceed as follows: a. Disconnect electrical connector at engine coolant temperature sensor. b. Disconnect and plug hose from manifold absolute pressure (MAP) sensor. c. Disconnect and plug hose from carburetor vacuum operated throttle modulator (VOTM). d. Connect vacuum pump to manifold port of MAP sensor, evacuate to at least 20 inches Hg. and hold. e. Start engine. Leave all vacuum hoses attached to air cleaner assembly when moving assembly to perform carburetor adjustments. The air cleaner assembly must be in place when measuring engine speeds. Prolonged engine idling may cause catalyst overheating and excessive underbody temperatures. 9. On all vehicles, ensure that ignition timing is set to specifications. 10. Check engine curb idle speed or A/C-OFF RPM, adjusting as necessary. Remove PCV valve from grommet and allow PCV to draw underhood air during idle fuel mixture check. 11. With transmission in neutral, run engine at approximately 2500 RPM for 15 seconds for each mixture check. 12. With engine idling at normal operating temperature, place transmission in specified gear, gradually open propane tool valve and watch for engine speed gain, if any, on tachometer. 13. When engine speed reaches a maximum and then begins to drop off, note the amount of speed gain. The propane cartridge must be in vertical position. If engine speed will not drop off, check propane cartridge gas supply. If necessary, repeat steps 11 through 13 with a new propane cartridge gas supply. 14. Compare measured speed gain to specified speed gain. 15. If measured speed gain is within specifications, proceed to step 20. If carburetor assembly is equipped with a tamper resistant idle adjustment feature, the carburetor must be removed from the vehicle. If idle fuel mixture adjustment is necessary, adjust mixture according to reset RPM specification. 16. If measured speed gain is zero and minimum speed gas specification is zero, proceed to step 19. 17. If measured speed gain is higher than specification, turn mixture screw(s) counterclockwise in equal amounts while simultaneously repeating steps Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Adjustments > Page 3234 10 through 13 until measured speed rise meets reset RPM specification. After final adjustment, proceed to step 20. 18. If measured speed gain is lower than speed gain specifications, turn idle mixture screw(s) clockwise in equal amounts while simultaneously repeating steps 10 through 13 until measured speed rise meets reset RPM specifications. After final adjustment, proceed to step 20. 19. If there is no RPM rise and the minimum speed gain specification is zero RPM, perform speed drop test as follows. Speed drop test information is specified with the artificial enrichment requirements whenever minimum speed gain specification is zero RPM. a. While observing tachometer, adjust mixture screw(s) clockwise by number of turns specified for speed drop test, noting drop in engine speed. b. If measured speed drop is equal to or drops off by more than the speed drop specification, return mixture screw(s) to position before adjustment and proceed to step 20. c. If measured speed drop is less than specified minimum speed drop specification, leave mixture screw(s) in adjusted position and repeat steps 10 through 19. 20. Install tamper resistant feature for carburetor idle fuel air adjustment. 21. Install PCV valve in grommet. 22. On vehicles equipped with feedback carburetor, proceed as follows: a. Connect electrical connector to engine coolant temperature sensor. b. Connect hose to MAP sensor. c. Connect hose to VOTM. d. Check curb idle speed and adjust to specification. 23. Remove all test equipment, reconnect all system components and install air cleaner. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, then translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor constantly monitors air temperature entering the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Description and Operation Accelerator Pump: Description and Operation Fig. 28 Temperature compensated accelerated pump. Motorcraft model 2150A carburetor The temperature compensated accelerator pump, Fig. 28, is used on vehicles equipped with the Motorcraft 2150A model carburetor, allows delivery of a large pump capacity to facilitate cold engine requirements and a smaller pump capacity during warm engine operation. The amount of fuel delivered during warm engine operation is a function of the rate at which the accelerator pedal is applied (fast application/low capacity, slow application/high capacity). The design incorporates a bypass bleed controlled by a vacuum operated valve. Normally, the input signal controlling the valve position is manifold vacuum switched by a PVS located in the engine coolant system. The valve is normally closed when no vacuum is applied, allowing full pump capacity during cold operation. With vacuum applied, the pump functions as a rate sensitive valve controlling the amount of fuel bypassed back to the carburetor fuel bowl and not delivered to the intake manifold air stream. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Description and Operation > Page 3242 Accelerator Pump: Testing and Inspection 1. Allow engine coolant to stabilize to ambient temperature. 2. Start engine and immediately check for vacuum at the temperature compensated accelerator pump valve. 3. When the engine is cold, no vacuum should be present. 4. Allow engine temperature to stabilize and check to ensure that a vacuum greater than 10 inches Hg is present at the temperature compensated accelerator pump valve. 5. If the vacuum signal to the valve is incorrect in either hot or cold mode, check vacuum hoses, connections and vacuum control valve. After a vacuum is verified, shut-off engine and connect a six inch section of clear tubing (5/32 inch inside diameter) between the temperature compensated accelerator pump valve. If no fuel is flowing, remove clear tubing and install vacuum hose to the temperature compensated accelerator pump valve. Turn ignition switch to off position. 6. With ignition switch in off position, remove carburetor air horn and air horn gasket. If the engine is warm, relieve pressure on fuel inlet needle by carefully depressing fuel bowl float. 7. Carefully remove float and needle assembly. 8. Remove enough fuel from the float bowl so that the temperature compensated accelerator pump bleed hole is just at or above bowl level. 9. Remove vacuum hose from valve and actuate accelerator pedal at a moderate or fast rate, and observe fuel discharge out of the temperature compensated accelerator pump bypass bleed. No fuel discharge should be observed from the bypass bleed. If fuel does discharge, replace valve. 10. Using a hand operated vacuum pump, apply a vacuum greater than 10 inches Hg to the temperature compensated accelerator pump valve. Actuate accelerator with a very quick action from idle to wide open throttle, fuel should discharge from the bypass bleed. If fuel is not discharged, replace temperature compensated accelerator pump valve. Install float and needle assembly, air horn and a new air horn gasket. Tighten attaching screws securely. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Description and Operation > Page 3243 Accelerator Pump: Adjustments Fig. 7 Pump stroke adjustment. The primary throttle shaft lever (overtravel lever) has three holes and the accelerating pump link has 2 to 4 holes to control the pump stroke for various atmospheric temperatures, operating conditions and specific engine applications, Fig. 7. Adjustment holes are not provided on the temperature compensated accelerator pump carburetors.The stroke should not be changed from the specified setting. 1. To release rod from retainer clip, press tab end of clip toward rod. Then, at the same time, press rod away from clip until it is disengaged. 2. Position clip over specified hole in overtravel lever. Press ends of clip together and insert operating rod through clip and lever. Release clip to engage rod. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid > Component Information > Locations Bowl Vent Solenoid: Locations At RH Side Of Carburetor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid > Component Information > Locations > Page 3247 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid > Component Information > Locations > Page 3248 Bowl Vent Solenoid: Testing and Inspection 1. Apply 12 volts to valve and ensure valve closes to block air passage. 2. Replace valve if it does not close when energized. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Solenoid > Component Information > Description and Operation > YFA Carburetor Feedback Solenoid Carburetor Solenoid: Description and Operation YFA Carburetor Feedback Solenoid Fig. 3 YFA feedback carburetor assembly This solenoid assembly is an integral part of the YFA feedback carburetor. The feedback solenoid operates as a pulse width modulated (dithering) solenoid, varying the air bleed into the idle and main fuel metering circuits. The solenoid responds to commands from the EEC-IV system, thereby varying the air/fuel ratio delivered to the engine, Fig. 3. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Solenoid > Component Information > Description and Operation > YFA Carburetor Feedback Solenoid > Page 3254 Carburetor Solenoid: Description and Operation 2150A Carburetor Feedback System Fig. 4 2150A feedback fuel control This carburetor feedback fuel control, utilizes a pulsing solenoid to introduce fresh air from the air cleaner into the idle and main system vacuum passages to lean the fuel and air mixture from the maximum rich condition (0% duty cycle-solenoid closed) to the maximum lean condition (100% duty cycle-solenoid fully open). The solenoid operates under the control of the EEC-IV system. This carburetor also incorporates a throttle position sensor, Fig. 4. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Plate > Component Information > Adjustments Choke Plate: 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Diagram Information and Instructions Electric Assist Choke: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3264 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3265 Electric Assist Choke: Electrical Diagrams Fig. 14 Charging System & Power Distribution (With Alternator Warning Indicator, Part 1 of 2). 1985 Gasoline Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3266 Fig. 14 Charging System & Power Distribution (With Alternator Warning Indicator, Part 2 of 2). 1985 Gasoline Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3267 Charging System & Power Distribution (With Ammeter, Part 1 of 2). 1985 Gasoline Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Diagram Information and Instructions > Page 3268 Charging System & Power Distribution (With Ammeter, Part 2 of 2). 1985 Gasoline Engine Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Page 3269 Electric Assist Choke: Description and Operation Fig. 45 Typical electric assist choke installation Most carbureted engine models are equipped with an electric assist choke. This device aids in reducing emissions of hydrocarbons (HC) and carbon monoxide (CO) during starting and warm-up (choke on) period. The electric assist choke is designed to give a more rapid choke opening at temperatures of about 54° to 74° F, or higher. It also provides a slower choke opening at temperatures below this point. The electric assist choke system does not change any carburetor service procedures and cannot be adjusted. If system is found out of calibration the heater control switch and/or choke unit must be replaced. The electric choke system, Fig. 45 consists of a choke cap, thermostatic spring, a bimetal temperature sensing disc (switch), and a ceramic positive temperature coefficient (PTC) heater. The choke is powered from terminal or tap of the alternator. Current is constantly supplied to the ambient temperature switch. The system is grounded through a ground strap connected to the carburetor body. At temperatures below approximately 60° F, the switch opens and no current is supplied to the ceramic heater located within the thermostatic spring. Normal thermostatic spring choking action then occurs. At temperatures above approximately 54°---74° F the temperature sensing switch closes and current is supplied to the ceramic heater. As the heater warms, it causes the thermostatic spring to pull the choke plates open within 1 - 1.25 minutes. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Page 3270 Electric Assist Choke: Testing and Inspection 1. Disconnect stator lead at connector leading from choke cap and connect a test light in series with stator lead and ground. 2. With engine running, test light should glow. 3. If light does not glow, repair or replace either the alternator or choke wire. 4. With engine running at normal operating temperature, place test light in series with choke terminal and alternator lead. If light does not glow, replace choke cap assembly. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Diagrams > Page 3271 Electric Assist Choke: Adjustments 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information > Locations Dashpot: Locations Attached To Bracket On LH Valve Cover Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information > Locations > Page 3275 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 91813 > Apr > 91 > Engine - Rough Idle/Hesitation/Backfire/Stalling Fuel: Customer Interest Engine - Rough Idle/Hesitation/Backfire/Stalling Article No. 91-8-13 04/17/91 FUEL - USE OF UNLEADED GASOLINES - TIPS TO AVOID LEAN AIR - FUEL CONDITIONS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY, F47, F53 1991 EXPLORER ISSUE: Rough idle, hesitation, poor throttle response, induction backfire and stalls during cold start/warm up may be caused by the poor volatility of some high octane premium grade unleaded fuels (91 octane or higher (R+M)/2). When compared to regular grade unleaded fuel (87 octane (R+M)/2), high octane premium grade unleaded fuel may cause long crank time. ACTION: Use a regular grade unleaded fuel in all vehicles, except where a premium unleaded fuel is recommended in the Owner Guide. If lean air-fuel type symptoms are experienced, determine the grade and brand of fuel used and offer the following service tips. ^ Advise those using a higher octane grade fuel to switch to a regular grade unleaded fuel. For those using a regular grade fuel, advise them to try another brand. ^ Do not advise using a higher octane unleaded fuel than is recommended for that specific engine. Ford engines are designed to perform best using a high quality regular grade unleaded fuel. ^ Only advise using a higher octane unleaded fuel to avoid potentially damaging spark knock or ping, but do so only after mechanical fixes are ineffective. NOTE: ALL UNLEADED GASOLINES USED SHOULD CONTAIN DETERGENT ADDITIVES THAT ARE ADVERTISED AS HAVING "KEEP CLEAN" OR "CLEAN UP" PERFORMANCE FOR BOTH INTAKE VALVES AND FUEL INJECTORS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline Fuel: All Technical Service Bulletins Fuel - California Reformulated Gasoline Article No. 96-10-7 05/06/96 FUEL - CALIFORNIA REFORMULATED GASOLINE (CARFG) - SERVICE TIP FORD: 1983-86 LTD 1983-88 EXP 1983-96 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1985-94 TEMPO 1986-96 TAURUS 1989-96 PROBE 1995-96 CONTOUR LINCOLN-MERCURY: 1980-83 MARK VI 1983-88 LN7 1983-96 COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1985-94 TOPAZ 1986-96 SABLE 1991-96 TRACER 1993-96 CONTINENTAL, MARK VIII 1995-96 MYSTIQUE LIGHT TRUCK: 1983-96 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1984-90 BRONCO II 1986-96 AEROSTAR 1987-96 F SUPER DUTY 1991-96 EXPLORER 1993-96 VILLAGER 1995-96 WINDSTAR ISSUE: California introduced CaRFG around March 1, 1996 and statewide it must be available at all service stations by June 1, 1996 to help reduce emissions and improve gasoline quality. It will replace the traditional gasoline sold in Northern California and improve the reformulated gasoline that has been sold in Southern California since January 1995. California Air Resources Board (CARB) projects smog forming emissions from motor vehicles to be reduced by about 15 percent. ACTION: The following text is provided to give some answers to some commonly asked questions by our customers. POSITION Ford Motor Company recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air. We have participated in vehicle and laboratory testing of CaRFG to make sure it is acceptable for our customers' use. There are no unusual vehicle performance concerns expected based upon these studies. The use of CaRFG will not affect Ford's new vehicle and/or emissions warranty. WHAT DOES CaRFG CONSIST OF? CaRFG consists of the same basic components as other gasolines, but it reduces pollution because of its cleaner burning components. Features are: ^ reduced aromatic hydrocarbons to form less smog emissions ^ added oxygenates to reduce emissions ^ decreases the amount of fuel evaporating from the vehicle ^ lowered sulfur content to provide more efficient operation of the vehicle's catalytic converter Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3289 ^ reduced benzene by about one-half IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES? CaRFG is a hazardous substance like conventional gasoline. Precautions should continue to be taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be siphoned or swallowed. HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE? Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of engine and fuel system components. Its basic properties are not significantly different than other cleaner burning gasolines that have been used in the U.S. for several years. If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but emission control system performance may be affected. Using gasolines other than CaRFG have substantially increased emissions from motor vehicles. WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY? No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have consistently approved the use of properly blended reformulated gasolines containing oxygenates. Further information about properly fueling your vehicle is included in the Owner Guide. WILL FUEL ECONOMY BE AFFECTED? A very small reduction in fuel economy of less than one-half mile per gallon is possible if the customer was using gasoline without oxygenates. This is attributed to the lower energy content of oxygenates which have been in all Southern California gasolines since January of 1995 and in some gasolines since the 1970's. Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc. Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same gasolines. For further details see TSB Article 95-12-2 for customer expectations regarding fuel economy. ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG? No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from the service station. California regulations require deposit control additives in CaRFG to minimize port fuel injector and intake valve deposits. WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG? Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been operating on gasolines similar to CaRFG for a number of years. However, considerable testing indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's recommendations regarding vehicle maintenance. WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE? CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor recovery systems to minimize the release of gasoline vapors while refueling. The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG has much lower sulfur than conventional gasoline. WAS CaRFG TESTED BEFORE INTRODUCTION? It was tested for over five million miles in more than 800 vehicles under the guidance of CARB including experts representing automobile manufacturers, gasoline suppliers, fleet operations and government. There was no increase in problems identified with the use of CaRFG. DOES CaRFG COST MORE? The price at the pump cannot be accurately predicted, although a modest increase is likely. The price of CaRFG is subject to the competitive forces in the marketplace. Many factors including production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices. WHERE CAN I GET MORE INFORMATION ON CaRFG? Additional information within the state of California on CaRFG is available from the California Air Resources Board toll-free at 1-800-922-7349 (within California only). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3290 OTHER APPLICABLE ARTICLES: 95-12-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 623000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 91813 > Apr > 91 > Engine - Rough Idle/Hesitation/Backfire/Stalling Fuel: All Technical Service Bulletins Engine - Rough Idle/Hesitation/Backfire/Stalling Article No. 91-8-13 04/17/91 FUEL - USE OF UNLEADED GASOLINES - TIPS TO AVOID LEAN AIR - FUEL CONDITIONS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY, F47, F53 1991 EXPLORER ISSUE: Rough idle, hesitation, poor throttle response, induction backfire and stalls during cold start/warm up may be caused by the poor volatility of some high octane premium grade unleaded fuels (91 octane or higher (R+M)/2). When compared to regular grade unleaded fuel (87 octane (R+M)/2), high octane premium grade unleaded fuel may cause long crank time. ACTION: Use a regular grade unleaded fuel in all vehicles, except where a premium unleaded fuel is recommended in the Owner Guide. If lean air-fuel type symptoms are experienced, determine the grade and brand of fuel used and offer the following service tips. ^ Advise those using a higher octane grade fuel to switch to a regular grade unleaded fuel. For those using a regular grade fuel, advise them to try another brand. ^ Do not advise using a higher octane unleaded fuel than is recommended for that specific engine. Ford engines are designed to perform best using a high quality regular grade unleaded fuel. ^ Only advise using a higher octane unleaded fuel to avoid potentially damaging spark knock or ping, but do so only after mechanical fixes are ineffective. NOTE: ALL UNLEADED GASOLINES USED SHOULD CONTAIN DETERGENT ADDITIVES THAT ARE ADVERTISED AS HAVING "KEEP CLEAN" OR "CLEAN UP" PERFORMANCE FOR BOTH INTAKE VALVES AND FUEL INJECTORS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 87239 > Nov > 87 > Rotunda Gas Chek Kit Requires Modification Fuel: All Technical Service Bulletins Rotunda Gas Chek Kit - Requires Modification Article No. FUEL SYSTEM - ROTUNDA "GAS-CHEK" KIT 87-23-9 TOOL MODIFICATION FORD: 1988 And Prior ALL CAR LINES LINCOLN-MERCURY: 1988 And Prior ALL CAR LINES LIGHT TRUCK: 1988 And Prior ALL LIGHT TRUCK LINES ISSUE: The Rotunda "Gas-Chek Kit" (Tool Number 113-00002) that you may have purchased prior to October, 1987 requires modification. The necessary components and new operating instructions will be shipped to you at no charge. This tool modification will provide greater accuracy when performing high fuel vapor pressure testing of gasoline. ACTION: To modify the Rotunda "Gas-Chek Kit", use the following service instructions. NOTE: This modification MUST be done because it will seriously affect the volatility tests. Figure 11 1. Remove adapter fitting attached to the 0-30 PSI gauge. CARE SHOULD BE TAKEN TO PREVENT DAMAGE TO GAUGE ASSEMBLY WHEN REMOVING FITTING. Throw away the adapter fitting, Figure 11. 2. Remove and throw away the aluminum vial, Figure 11. 3. Remove plastic thermos cup cap and throw away, Figure 11. 4. Remove the set of instructions from the lid of the Gas-Chek plastic storage box and throw them away. NOTE: USE ONLY THE NEW instruction booklet that is furnished in the modification kit. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 87239 > Nov > 87 > Rotunda Gas Chek Kit Requires Modification > Page 3299 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline Fuel: All Technical Service Bulletins Fuel - California Reformulated Gasoline Article No. 96-10-7 05/06/96 FUEL - CALIFORNIA REFORMULATED GASOLINE (CARFG) - SERVICE TIP FORD: 1983-86 LTD 1983-88 EXP 1983-96 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1985-94 TEMPO 1986-96 TAURUS 1989-96 PROBE 1995-96 CONTOUR LINCOLN-MERCURY: 1980-83 MARK VI 1983-88 LN7 1983-96 COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1985-94 TOPAZ 1986-96 SABLE 1991-96 TRACER 1993-96 CONTINENTAL, MARK VIII 1995-96 MYSTIQUE LIGHT TRUCK: 1983-96 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1984-90 BRONCO II 1986-96 AEROSTAR 1987-96 F SUPER DUTY 1991-96 EXPLORER 1993-96 VILLAGER 1995-96 WINDSTAR ISSUE: California introduced CaRFG around March 1, 1996 and statewide it must be available at all service stations by June 1, 1996 to help reduce emissions and improve gasoline quality. It will replace the traditional gasoline sold in Northern California and improve the reformulated gasoline that has been sold in Southern California since January 1995. California Air Resources Board (CARB) projects smog forming emissions from motor vehicles to be reduced by about 15 percent. ACTION: The following text is provided to give some answers to some commonly asked questions by our customers. POSITION Ford Motor Company recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air. We have participated in vehicle and laboratory testing of CaRFG to make sure it is acceptable for our customers' use. There are no unusual vehicle performance concerns expected based upon these studies. The use of CaRFG will not affect Ford's new vehicle and/or emissions warranty. WHAT DOES CaRFG CONSIST OF? CaRFG consists of the same basic components as other gasolines, but it reduces pollution because of its cleaner burning components. Features are: ^ reduced aromatic hydrocarbons to form less smog emissions ^ added oxygenates to reduce emissions ^ decreases the amount of fuel evaporating from the vehicle ^ lowered sulfur content to provide more efficient operation of the vehicle's catalytic converter Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3305 ^ reduced benzene by about one-half IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES? CaRFG is a hazardous substance like conventional gasoline. Precautions should continue to be taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be siphoned or swallowed. HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE? Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of engine and fuel system components. Its basic properties are not significantly different than other cleaner burning gasolines that have been used in the U.S. for several years. If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but emission control system performance may be affected. Using gasolines other than CaRFG have substantially increased emissions from motor vehicles. WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY? No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have consistently approved the use of properly blended reformulated gasolines containing oxygenates. Further information about properly fueling your vehicle is included in the Owner Guide. WILL FUEL ECONOMY BE AFFECTED? A very small reduction in fuel economy of less than one-half mile per gallon is possible if the customer was using gasoline without oxygenates. This is attributed to the lower energy content of oxygenates which have been in all Southern California gasolines since January of 1995 and in some gasolines since the 1970's. Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc. Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same gasolines. For further details see TSB Article 95-12-2 for customer expectations regarding fuel economy. ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG? No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from the service station. California regulations require deposit control additives in CaRFG to minimize port fuel injector and intake valve deposits. WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG? Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been operating on gasolines similar to CaRFG for a number of years. However, considerable testing indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's recommendations regarding vehicle maintenance. WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE? CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor recovery systems to minimize the release of gasoline vapors while refueling. The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG has much lower sulfur than conventional gasoline. WAS CaRFG TESTED BEFORE INTRODUCTION? It was tested for over five million miles in more than 800 vehicles under the guidance of CARB including experts representing automobile manufacturers, gasoline suppliers, fleet operations and government. There was no increase in problems identified with the use of CaRFG. DOES CaRFG COST MORE? The price at the pump cannot be accurately predicted, although a modest increase is likely. The price of CaRFG is subject to the competitive forces in the marketplace. Many factors including production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices. WHERE CAN I GET MORE INFORMATION ON CaRFG? Additional information within the state of California on CaRFG is available from the California Air Resources Board toll-free at 1-800-922-7349 (within California only). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3306 OTHER APPLICABLE ARTICLES: 95-12-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 623000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 87239 > Nov > 87 > Rotunda Gas Chek Kit - Requires Modification Fuel: All Technical Service Bulletins Rotunda Gas Chek Kit - Requires Modification Article No. FUEL SYSTEM - ROTUNDA "GAS-CHEK" KIT 87-23-9 TOOL MODIFICATION FORD: 1988 And Prior ALL CAR LINES LINCOLN-MERCURY: 1988 And Prior ALL CAR LINES LIGHT TRUCK: 1988 And Prior ALL LIGHT TRUCK LINES ISSUE: The Rotunda "Gas-Chek Kit" (Tool Number 113-00002) that you may have purchased prior to October, 1987 requires modification. The necessary components and new operating instructions will be shipped to you at no charge. This tool modification will provide greater accuracy when performing high fuel vapor pressure testing of gasoline. ACTION: To modify the Rotunda "Gas-Chek Kit", use the following service instructions. NOTE: This modification MUST be done because it will seriously affect the volatility tests. Figure 11 1. Remove adapter fitting attached to the 0-30 PSI gauge. CARE SHOULD BE TAKEN TO PREVENT DAMAGE TO GAUGE ASSEMBLY WHEN REMOVING FITTING. Throw away the adapter fitting, Figure 11. 2. Remove and throw away the aluminum vial, Figure 11. 3. Remove plastic thermos cup cap and throw away, Figure 11. 4. Remove the set of instructions from the lid of the Gas-Chek plastic storage box and throw them away. NOTE: USE ONLY THE NEW instruction booklet that is furnished in the modification kit. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 87239 > Nov > 87 > Rotunda Gas Chek Kit - Requires Modification > Page 3311 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Fuel Tank Filler Cap - New Design Available Fuel Filler Cap: Technical Service Bulletins Fuel Tank Filler Cap - New Design Available FUEL SYSTEM - HIGH FLOW "PRE-VENT" FULL TANK FILLER CAP Article No. 88-25-13 LIGHT TRUCK: 1983-88 ECONOLINE 1983-86 F-SERIES ISSUE: A new cam-lock high flow "Pre-vent" filler cap is available for service. The new filler cap encourages slower loosening for more gradual venting of fuel tank pressure. The "Pre-vent" filler cap has a black plastic cover. Trucks with exposed filler caps or trucks with filler caps covered by fuel filler doors can use the new filler cap. ACTION: Install a new high flow "Pre-vent" filler cap for service: ^ In areas that sell "winter grade" fuel in hot weather. ^ For owners who frequently overfill fuel tanks. ^ For owners concerned about normal venting of fuel tank pressure. FIGURE 4 The new filler cap meets or exceeds the performance of all other filler caps released by Ford Motor Company, Figure 4. NOTE: USE THE NEW FILLER CAP TO REPLACE FILLER CAPS LISTED IN TSB 87-15-13. PART NUMBER PART NAME CLASS E8TZ-9030-C Cap Assembly C ARTICLE SUPERSEDED: 87-15-13 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODE: 4500 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: FUEL SUPPLY LINES ON EFI ENGINES WILL REMAIN PRESSURIZED FOR SOME PERIOD OF TIME AFTER THE ENGINE IS SHUT OFF. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. FUEL SYSTEM PRESSURE RELIEF - EFI ENGINES Before opening the fuel system on vehicles with EFI engines, relieve fuel pressure as follows: 1. Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch or the in-line high pressure fuel pump. 2. Crank engine for approximately ten seconds. Note: Engine may start and run for a short time. If so, crank engine an additional 5 seconds after engine stalls. 3. Re-connect the electrical connector that was disconnected in step 1 and disconnect battery ground cable. Alternative Method Some EFI vehicles have a port (fitting) on the fuel rail used for measuring fuel pressure. If so equipped, use the following method: Install fuel pressure relief tool No. T80L-9974-B or equivalent to measuring port on engine fuel rail. - Position drain hose in suitable container, then depress relief button. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Injector Tester/Cleaner Service Tips Fuel Injector: Technical Service Bulletins Fuel System - Injector Tester/Cleaner Service Tips Article No. FUEL SYSTEM - INJECTOR TESTER/CLEANER 87-17-5 SERVICE TIPS FORD: 1983-88 ALL CAR LINES LINCOLN-MERCURY: 1983-88 ALL CAR LINES LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A Fuel injector Tester/Cleaner has not been approved by Ford Motor Company for cleaning Central Fuel Injected (CFI) vehicles. ACTION: If a CFI system's fuel injector is contaminated, replace the injector using the appropriate shop manual procedure. NOTE: The unauthorized use of an lnjector Tester/Cleaner on CFI systems is not a reimbursable labor operation. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Injector Tester/Cleaner Service Tips > Page 3328 Fuel Injector: Technical Service Bulletins Engine - Rough Idle or Stumble Article No. 93-11-4 05/26/93 ^ FUEL INJECTORS - NON-DEPOSIT RESISTANT TYPE - DEPOSIT FORMATION ^ IDLE - ROUGH - LEAN FUEL FLOW CAUSED BY FUEL INJECTOR PINTLE DEPOSIT FORMATION ^ STUMBLE - LEAN FUEL FLOW CAUSED BY FUEL INJECTOR PINTLE DEPOSIT FORMATION FORD: 1988-90 TAURUS, TEMPO 1988-91 MUSTANG LINCOLN-MERCURY: 1988-89 CONTINENTAL 1988-90 SABLE, TOPAZ 1988-91 MARK VII LIGHT TRUCK: 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F-47, F-53 This TSB article is being republished in its entirety to correct the part number for the 7.5L engine injector assembly. ISSUE: A stumble or rough idle condition may be caused by lean fuel flow resulting from pintle deposit formation on non-deposit resistant fuel injectors. These non-deposit resistant fuel injectors are susceptible to pintle deposit formation. ACTION: If service is required, install deposit resistant injectors. These Deposit Resistant Injectors (DRI'S) are acceptable service replacements for non-deposit resistant injectors that exhibit lean fuel flow. Refer to the DRI Replacement Chart for correct parts usage. Parts Block NOTE: FUEL INJECTOR REPLACEMENT IS ONLY ALLOWED WHEN LEAN FLOW IS VERIFIED BY UTILIZING THE SERVICE BAY DIAGNOSTIC SYSTEM (SBDS) OR ROTUNDA FUEL INJECTOR CLEANER (113-0001). SUPERSEDES: 92-24-5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Injector Tester/Cleaner Service Tips > Page 3329 WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1991 Lincolns, Basic Warranty Coverage, Emissions Warranty Coverage LABOR OPERATION TIME DEALER CODING BASIC PART NO. CONDITION CODE 9F593 49 OASIS CODES: 404000, 608000, 608400, 611000, 611500 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Injector Tester/Cleaner Service Tips > Page 3330 Fuel Injector: Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 851621 > Aug > 85 > Engine - Hard Starting/Long Crank Times Fuel Pressure Regulator: Customer Interest Engine - Hard Starting/Long Crank Times Article No. 85-16-21 HARD START - LONG CRANK TIMES (5.0L EFI) LIGHT TRUCK F-SERIES, BRONCO Long crank time and/or hard start with a cold or hot engine may be the result of a leaking fuel pressure regulator. The leak (internal) lets the pressure leak down at the fuel rail. This causes a no fuel or starvation until the pressure is built up again. Perform the following to alleviate this concern. NOTE: Prior to any repair: Run the engine several minutes and shut down. Rough/unstable idle with a lower than normal vacuum may indicate stuck/leaky injectors which would contribute to a loss in system pressure. Check the fuel system for external leaks - lines, connections at the filter, fuel rails, pressure regulator and injectors. Repair as necessary. If no leaks are present: Turn the ignition switch to "On" position and hold for two seconds. DO NOT CRANK ENGINE. Repeat ten times. If engine now starts normally, it indicates a fuel system pressure leak down/loss. Continue with the following procedure. If it doesn't start, then the problem is not pressure regulator related. Refer to engine diagnostic procedure. 1. Relieve pressure in fuel rail per Section 24-50-28, 1985 Light Truck Shop Manual, Volume B. 2. Remove the fuel pressure regulator. 3. Inspect the gasket and O-ring for cracks and cuts, replace as required. 4. Connect the vacuum gauge to the fuel return tube (7/32-inch diameter tube centered on baseplate). 5. Apply 20 inches Hg. of vacuum. 6. Vacuum must not drop below 10 inches Hg. in 10 seconds. If vacuum check does not drop below 10 inches Hg. in 10 seconds, the valve seat is good. Reassemble the regulator to the fuel manifold rail and check the fuel pump for a leaky check valve. If the vacuum indicates a leaky valve seat in the pressure regulator, replace the regulator. PART NUMBER PART NAME CLASS E3FZ-9C968-A Fuel Pressure Regulator R OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9968B85 TIME: 1.1 Hrs. DLR. CODING: Basic Part No. 9C968 - Code: N3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 851621 > Aug > 85 > Engine - Hard Starting/Long Crank Times Fuel Pressure Regulator: All Technical Service Bulletins Engine - Hard Starting/Long Crank Times Article No. 85-16-21 HARD START - LONG CRANK TIMES (5.0L EFI) LIGHT TRUCK F-SERIES, BRONCO Long crank time and/or hard start with a cold or hot engine may be the result of a leaking fuel pressure regulator. The leak (internal) lets the pressure leak down at the fuel rail. This causes a no fuel or starvation until the pressure is built up again. Perform the following to alleviate this concern. NOTE: Prior to any repair: Run the engine several minutes and shut down. Rough/unstable idle with a lower than normal vacuum may indicate stuck/leaky injectors which would contribute to a loss in system pressure. Check the fuel system for external leaks - lines, connections at the filter, fuel rails, pressure regulator and injectors. Repair as necessary. If no leaks are present: Turn the ignition switch to "On" position and hold for two seconds. DO NOT CRANK ENGINE. Repeat ten times. If engine now starts normally, it indicates a fuel system pressure leak down/loss. Continue with the following procedure. If it doesn't start, then the problem is not pressure regulator related. Refer to engine diagnostic procedure. 1. Relieve pressure in fuel rail per Section 24-50-28, 1985 Light Truck Shop Manual, Volume B. 2. Remove the fuel pressure regulator. 3. Inspect the gasket and O-ring for cracks and cuts, replace as required. 4. Connect the vacuum gauge to the fuel return tube (7/32-inch diameter tube centered on baseplate). 5. Apply 20 inches Hg. of vacuum. 6. Vacuum must not drop below 10 inches Hg. in 10 seconds. If vacuum check does not drop below 10 inches Hg. in 10 seconds, the valve seat is good. Reassemble the regulator to the fuel manifold rail and check the fuel pump for a leaky check valve. If the vacuum indicates a leaky valve seat in the pressure regulator, replace the regulator. PART NUMBER PART NAME CLASS E3FZ-9C968-A Fuel Pressure Regulator R OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9968B85 TIME: 1.1 Hrs. DLR. CODING: Basic Part No. 9C968 - Code: N3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Carburetor Fuel Pressure: Specifications Carburetor 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Carburetor > Page 3352 Fuel Pressure: Specifications Fuel Injection FUEL SYSTEM SPECIFICATIONS Pressure Key On Engine Off ............................................................................................................................... ................................................... 35-45 psi Engine Idling .................................................................... ....................................................................................................................... 28-38 psi Volume A minimum of 170 ml (5.6 oz) in 10 seconds. WARNING: Fuel supply lines will remain pressurized for some period of time after the engine is shut off. Before opening the fuel system, relieve the fuel pressure. FUEL PRESSURE RELIEF PROCEDURE - Locate and disconnect the electrical connection to either the fuel pump relay, the inertia switch, or the in-line high pressure fuel pump. - Crank engine for about ten seconds. NOTE: Engine may start and run for a short time. If so, crank engine an additional five seconds after engine stalls. - Reconnect the electrical connector that was disconnected in the first step. - Disconnect negative battery cable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3353 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3369 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures Fuel Return Line: Technical Service Bulletins Fuel Line Spring Lock Coupling - Service Procedures FUEL LINE SPRING LOCK COUPLING - SUMMARY Article No. OF SERVICE PROCEDURES AND REVISED TOOLS 87-3-8 FORD 1986 LTD 1986-87 ESCORT, EXP, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY 1986 MARQUIS, CAPRI 1986-87 LYNX, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK 1985-87 RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO ISSUE: This article summarizes the overall service procedure to be used for disconnecting and connecting the fuel line spring lock coupling. In addition, the service tools and service part O-rings have been recently revised. The service tools (available March, 1987) D87L-9280-A (3/8") and D87L-9280-B (1/2") used to disconnect the spring lock coupling will now fit around the rubber cover on the fuel line allowing an easier disconnect. The O-ring part numbers were changed to specify color. The fuel resistant O-rings 390846-S96 (3/8") and 390847-S96 (1/2") will be BROWN in color while the A/C refrigerant Orings will continue to be BLACK. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3374 Figure 5 ACTION: To properly disconnect and connect the fuel line spring coupling, use the illustrated service procedure on page 44 of this TSB, Figure 5. This illustration should also be used in place of the following 1985 through 1987 Car and Light Truck Shop Manual pages: 1985 Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-05-17 1986 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3375 Car Shop Manual, Volume D, Section 24-50-11 Car Shop Manual, Volume E, Section 24-50-14 Taurus/Sable Shop Manual, Section 24-50-11 Ranger/Bronco II Shop Manual, Section 24-03-11 Aerostar Shop Maunal, Section 9-06-15 / 9-06-16 Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-50-35 1987 Car Shop Manual, Volume D, Section 24-50-11 Car Shop Manual, Volume E, Section 24-50-17 Taurus/Sable Shop Manual, Section 24-50-12 Ranger/Bronco II Shop Manual, Section 24-03-10 / 24-05-10 Aerostar Shop Manual, Section 9-02-10 / 9-06-17 / 9-06-18 Light Truck Shop Manual, Volume B, Section 24-05-14 / 24-10-9 / 27-10-20 / 24-50-34 NOTE: The following items should be noted when service is required. ^ Use the specified tool or equivalent. ^ Inspect for missing or damaged O-rings. ^ Use the specified fuel resistant O-rings (BROWN). ^ Lubricate the O-ring with clean engine oil. ^ Check to make sure that the fitting is locked. PART NUMBER PART NAME CLASS 390846-S96 O-Ring 3/8" (Brown) S 390847-S96 O-Ring 1/2" (Brown) S OTHER APPLICABLE ARTICLES: Supersedes 86-12-17, 86-12-13 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Shut-off Solenoid > Fuel Shut-off Solenoid Relay > Component Information > Locations Fuel Shut-off Solenoid Relay: Locations LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures Fuel Supply Line: Technical Service Bulletins Fuel Line Spring Lock Coupling - Service Procedures FUEL LINE SPRING LOCK COUPLING - SUMMARY Article No. OF SERVICE PROCEDURES AND REVISED TOOLS 87-3-8 FORD 1986 LTD 1986-87 ESCORT, EXP, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY 1986 MARQUIS, CAPRI 1986-87 LYNX, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK 1985-87 RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO ISSUE: This article summarizes the overall service procedure to be used for disconnecting and connecting the fuel line spring lock coupling. In addition, the service tools and service part O-rings have been recently revised. The service tools (available March, 1987) D87L-9280-A (3/8") and D87L-9280-B (1/2") used to disconnect the spring lock coupling will now fit around the rubber cover on the fuel line allowing an easier disconnect. The O-ring part numbers were changed to specify color. The fuel resistant O-rings 390846-S96 (3/8") and 390847-S96 (1/2") will be BROWN in color while the A/C refrigerant Orings will continue to be BLACK. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3384 Figure 5 ACTION: To properly disconnect and connect the fuel line spring coupling, use the illustrated service procedure on page 44 of this TSB, Figure 5. This illustration should also be used in place of the following 1985 through 1987 Car and Light Truck Shop Manual pages: 1985 Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-05-17 1986 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3385 Car Shop Manual, Volume D, Section 24-50-11 Car Shop Manual, Volume E, Section 24-50-14 Taurus/Sable Shop Manual, Section 24-50-11 Ranger/Bronco II Shop Manual, Section 24-03-11 Aerostar Shop Maunal, Section 9-06-15 / 9-06-16 Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-50-35 1987 Car Shop Manual, Volume D, Section 24-50-11 Car Shop Manual, Volume E, Section 24-50-17 Taurus/Sable Shop Manual, Section 24-50-12 Ranger/Bronco II Shop Manual, Section 24-03-10 / 24-05-10 Aerostar Shop Manual, Section 9-02-10 / 9-06-17 / 9-06-18 Light Truck Shop Manual, Volume B, Section 24-05-14 / 24-10-9 / 27-10-20 / 24-50-34 NOTE: The following items should be noted when service is required. ^ Use the specified tool or equivalent. ^ Inspect for missing or damaged O-rings. ^ Use the specified fuel resistant O-rings (BROWN). ^ Lubricate the O-ring with clean engine oil. ^ Check to make sure that the fitting is locked. PART NUMBER PART NAME CLASS 390846-S96 O-Ring 3/8" (Brown) S 390847-S96 O-Ring 1/2" (Brown) S OTHER APPLICABLE ARTICLES: Supersedes 86-12-17, 86-12-13 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3386 Fuel Supply Line: Technical Service Bulletins Fuel System - Connector Service Procedure Article No. 85-19-20 FUEL SYSTEM SERVICE PROCEDURE FOR NYLON FUEL TUBES AND PUSH CONNECT FITTINGS LIGHT TRUCK 1985 RANGER, BRONCO II, E & F SERIES WITH EFI ENGINES If services are required on vehicles equipped with nylon fuel tubes and EFI fuel systems, service parts and service procedures are being released. The following procedure clarifies Shop Manual Section 24-50 of the 1985 Truck Shop Manual, Engine - Volume B, and must be adhered to: MAJOR SERVICE OPERATIONS Fuel Lines Vehicles equipped with nylon fuel tubes and push connect fittings have three types of service that can be performed to the fuel lines; replacing nylon tubing (splicing nylon to nylon), replacing push connector and replacing damaged push connect tube end. These three methods follow: Splicing Nylon to Nylon 1. Relieve fuel system pressure as outlined in the 1985 Car/Truck Shop Manual - Powertrain Section 24-50. Read cautionary note prior to relieving pressurized fuel system. 2. Cut out damaged section of tubing and retain as a guide. 3. Cut a section of nylon service tubing (type 11 or 12 available in 5/16 and 3/8 inch sizes) to the same length as the damaged section of tubing. Figure 23 - Tubing Splice 4. Select the proper (5/16 and 3/8 inch) barbed connectors for completing the splice. Two connectors are required for each splice (Figure 23). NOTE: To make hand insertion of the barbed connectors into the nylon easier, the tube end must be soaked in a cup of boiling water for one minute immediately before pushing the barbs into the nylon. Refer to Figure 23 for all splicing service combinations. 5. Install the barbed connectors into each end of the replacement tubing using boiling water as outlined. 6. Install clips onto any tubes which might be difficult to access once the final splices are completed. a. Install four (4) Keystone clamps (part number 377931) onto the original nylon tubing (loosely) before beginning Step 7. 7. Complete the splice of the replacement nylon to the original nylon tubing at both ends. (Use the boiling water method mentioned previously, to get the required number of barbs engaged, as shown in Figure 23). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3387 a. Tighten the clamps in the locations shown in Figure 23. 8. Install any remaining clips which were removed for this service and check that the tubes are secure in the original clips. 9. Start engine and check for leaks. Replacing Damaged Push Connectors 1. Relieve fuel system pressure as outlined in the 1985 Car/Truck Shop Manual - Powertrain Section 24-50. Read cautionary note prior to relieving pressurized fuel system. NOTE: Damaged push connectors must be discarded and replaced with new push connectors. If only the retaining clip is damaged, replace the clip. 2. Disconnect the damaged push connector. Be sure to bend the shipping tab to the side before removing retaining clip. Figure 22 - FUEL LINE SERVICE PARTS 3. Select the proper size replacement push connector and nylon tube assembly (Figure 22). 4. Cut out a section of the original nylon tube to the same length as the nylon tube attached to the new push connector. 5. Install proper barbed connector into the replacement nylon assembly. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3388 Figure 23 - Tubing Splice NOTE: To make hand insertion of the barbed connectors into the nylon easier, the tube end must be soaked in a cup of boiling water for one minute immediately before pushing the barbs into the nylon. Refer to Figure 23 for all splicing service combinations. a. Put two (2) Keystone clamps (part number 377931) onto the original nylon tubing (loosely) before beginning Step 6. 6. Complete the splice by connecting the barbed connector to the original nylon. Refer to Figure 23 for the proper barb insertion. a. Tighten the clamps in the locations shown in Figure 23. 7. Connect the new connector assembly to the steel tube end. Pull back on the connection to insure that the fittings have completely engaged and are locked. 8. Check that the underbody clips are properly securing the fuel tubes. 9. Start engine and check for fuel leaks. Replacing Damaged Steel Push Connect Tube Ends 1. Relieve fuel system pressure as outlined in the 1985 Car/Truck Shop Manual - Powertrain Section 24-50. Read cautionary note prior to relieving pressurized fuel systems. 2. Using a tube cutter, remove the damaged push connect tube end at a convenient distance from the end. NOTE: Allow for adequate room to tighten a union with a wrench at this location. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3389 Figure 22 - FUEL LINE SERVICE PARTS 3. Choose a proper replacement push connect tube end (Figure 22). 4. If required, form a new tube end to the same shape as the damaged tube end which was removed. 5. Select the proper size union (Figure 22) and attach the new steel tube end to the original tube. 6. Clean off the steel tube end and insert the push connector onto the tube. (A new retainer clip is recommended.) Pull back on the connection to insure that fittings have completely engaged and are locked. 7. Check that the underbody clips are properly securing the fuel tubes. 8. Start engine and check for leaks. Refer to Figure 22 for an illustration of the following part numbers: ILLUS PART NUMBER PART NAME CLASS NO. 4 389351-S43 Union - 5/16 BS 4 390080-S43 Union - 1/4 BS 2 N803430-S Union - 1/4 BS 1 N803431-S Union - 5/16 RS 6 E3FZ-9291-B Tube - 1/4 Straight B 6 E3FZ-9291-C Tube - 5/16 Straight B 7 E3FZ-9291-D Tube - 5/16 Elbow B 5 E3FZ-9291-E Tube - 5/16 Steel RM 5 E3FZ-9291-F Tube - 1/4 Steel C 3 E3FZ-9291-G Tube - 1/4 Bulk C Nylon 3 E3FZ-9291-H Tube - 5/16 Bulk B Nylon 7 E5TZ-9291-AH Tube - 3/8 - 5/16 C Elbow 7 E5TZ-9291-AG Tube - 3/8 - 3/8 C Elbow 6 E5TZ-9291-AF Tube - 3/8 - 3/8 C Straight 3 E5TZ-9291-A Tube - 3/8 Bulk C Nylon 8 N804407-S 3/8 x 3/8 Connector S Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3390 Figure 24 - TYPICAL PUSH CONNECT FITTINGS Refer to Figure 24 for an illustration of typical push connect fittings. PART NUMBER PART NAME CLASS N802239-S Retainer - 5/16 BG Hairpin (White) N802241-S Retainer - 3/8 BG Hairpin (Black) N802710-S190 Retainer - 1/4 BG Duck Bill (White) OTHER APPLICABLE ARTICLES: 85-6-19 Supersedes: 85-4-38 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 9999A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 9291 - Code: 73 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention > Page 3396 Fuel Gauge Sender: Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention > Page 3397 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Auxiliary Tank Fuel Gauge Sender Fuel Gauge Sender: Locations Auxiliary Tank Fuel Gauge Sender Attached To Rear Fuel Tank Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Auxiliary Tank Fuel Gauge Sender > Page 3400 Fuel Gauge Sender: Locations Fuel Gauge Sender Attached To Rear Fuel Tank Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector Switch > Component Information > Locations > Tank Selector Relay Fuel Tank Selector Switch: Locations Tank Selector Relay Left Rear Corner Of Engine Compartment (next to fuel cut-off relay). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector Switch > Component Information > Locations > Tank Selector Relay > Page 3405 Fuel Tank Selector Switch: Locations Fuel Tank Selector Switch LH Side Of I/P Near Fuse Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Locations Fuel Tank Switching Valve: Locations Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Recalls for Fuel Tank Vent: > NHTSA87V113000 > Jul > 87 > Recall 87V113000: EVAP System Modification Fuel Tank Vent: Recalls Recall 87V113000: EVAP System Modification EXPULSION OF FUEL DUE TO OVER PRESSURIZATION. FUEL OR FUEL VAPORS IN THE PRESENCE OF AN IGNITION SOURCE CAN CAUSE A FIRE. MODIFICATION OF THE BASE FUEL VENTING AND EMISSION CONTROL SYSTEM TO REDUCE OPERATING TEMPERATURES AND FUEL SYSTEM PRESSURES. SYSTEM: FUEL. VEHICLE DESCRIPTION: AMBULANCE, FORD ECONOLINE E350 CUTAWAY CHASSIS AND VANS,EQUIPPED WITH 7.5 LITER ENGINES. 1983 FORD TRUCK E350 1983 FORD TRUCK ECONOLINE 1984 FORD TRUCK E350 1984 FORD TRUCK ECONOLINE 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE 1987 FORD TRUCK E350 1987 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Recalls for Fuel Tank Vent: > NHTSA87V111000 > Jul > 87 > Recall 87V111000: Vapor Valve Grommet Replacement Fuel Tank Vent: Recalls Recall 87V111000: Vapor Valve Grommet Replacement FUEL LEAK AT THE TOP OF THE FRONT FUEL TANK IN THE AREA OF THE VAPOR VALVE GROMMET. GROMMET MAY SPLIT DUE TO COMPRESSIVE LOAD WHEN INSTALLED IN THE FUEL TANK. FUEL MAY LEAK FROM VAPOR VALVE AND BECOME THE SOURCE OF FUEL FOR A FIRE. INSTALLATION OF A NEWLY DESIGNED VAPOR VALVE GROMMET. SYSTEM: FUEL/TANK VAPOR VALVE. VEHICLE DESCRIPTION: AMBULANCE, ECONOLINE E350 VANS AND CUTAWAY CHASSIS WITH 7.5 LITER ENGINES. 1984 FORD TRUCK E350 1984 FORD TRUCK ECONOLINE 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE 1987 FORD TRUCK E350 1987 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > NHTSA87V113000 > Jul > 87 > Recall 87V113000: EVAP System Modification Fuel Tank Vent: All Technical Service Bulletins Recall 87V113000: EVAP System Modification EXPULSION OF FUEL DUE TO OVER PRESSURIZATION. FUEL OR FUEL VAPORS IN THE PRESENCE OF AN IGNITION SOURCE CAN CAUSE A FIRE. MODIFICATION OF THE BASE FUEL VENTING AND EMISSION CONTROL SYSTEM TO REDUCE OPERATING TEMPERATURES AND FUEL SYSTEM PRESSURES. SYSTEM: FUEL. VEHICLE DESCRIPTION: AMBULANCE, FORD ECONOLINE E350 CUTAWAY CHASSIS AND VANS,EQUIPPED WITH 7.5 LITER ENGINES. 1983 FORD TRUCK E350 1983 FORD TRUCK ECONOLINE 1984 FORD TRUCK E350 1984 FORD TRUCK ECONOLINE 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE 1987 FORD TRUCK E350 1987 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > NHTSA87V111000 > Jul > 87 > Recall 87V111000: Vapor Valve Grommet Replacement Fuel Tank Vent: All Technical Service Bulletins Recall 87V111000: Vapor Valve Grommet Replacement FUEL LEAK AT THE TOP OF THE FRONT FUEL TANK IN THE AREA OF THE VAPOR VALVE GROMMET. GROMMET MAY SPLIT DUE TO COMPRESSIVE LOAD WHEN INSTALLED IN THE FUEL TANK. FUEL MAY LEAK FROM VAPOR VALVE AND BECOME THE SOURCE OF FUEL FOR A FIRE. INSTALLATION OF A NEWLY DESIGNED VAPOR VALVE GROMMET. SYSTEM: FUEL/TANK VAPOR VALVE. VEHICLE DESCRIPTION: AMBULANCE, ECONOLINE E350 VANS AND CUTAWAY CHASSIS WITH 7.5 LITER ENGINES. 1984 FORD TRUCK E350 1984 FORD TRUCK ECONOLINE 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE 1987 FORD TRUCK E350 1987 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > Recalls: > NHTSA85V061000 > May > 85 > Recall 85V061000: Fuel/Water Separator Shield Fuel/Water Separator: Recalls Recall 85V061000: Fuel/Water Separator Shield WHEN FRONTALLY IMPACTED INTO A FIXED BARRIER AT 30 MPH, AS SPECIFIED IN FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) NO. 301, THE LEFT FRAME RAILS OF SUCH VEHICLES MAY DISPLACE INBOARD, PINCHING THE FUEL/WATER SEPARATOR CANISTER BETWEEN THE FRAME RAIL AND ENGINE SUFFICIENTLY TO DISPLACE THE FUEL/WATER SEPARATOR DRAIN ROD, ALLOWING THE CONTENTS OF THE CANISTER TO DRAIN. CONSEQUENCE OF DEFECT: FUEL LEAK DURING OR AFTER A CRASH INCREASES THE POSSIBILITY OF A FIRE. INSTALL A CANISTER SHIELD, A REVISED DESIGN DRAIN ROD SHIELD, AND MODIFY FUEL/WATER SEPARATOR MOUNTING BRACKET. VEHICLE DESCRIPTION: VANS, SUPER VANS, SUPER WAGONS AND CLUB WAGONS EQUIPPED WITH 6.9 LITER DIESEL ENGINES. SYSTEM: FUEL/FMVSS 301. 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK ECONOLINE 1984 FORD TRUCK E250 1984 FORD TRUCK E350 1984 FORD TRUCK ECONOLINE 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA85V061000 > May > 85 > Recall 85V061000: Fuel/Water Separator Shield Fuel/Water Separator: All Technical Service Bulletins Recall 85V061000: Fuel/Water Separator Shield WHEN FRONTALLY IMPACTED INTO A FIXED BARRIER AT 30 MPH, AS SPECIFIED IN FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) NO. 301, THE LEFT FRAME RAILS OF SUCH VEHICLES MAY DISPLACE INBOARD, PINCHING THE FUEL/WATER SEPARATOR CANISTER BETWEEN THE FRAME RAIL AND ENGINE SUFFICIENTLY TO DISPLACE THE FUEL/WATER SEPARATOR DRAIN ROD, ALLOWING THE CONTENTS OF THE CANISTER TO DRAIN. CONSEQUENCE OF DEFECT: FUEL LEAK DURING OR AFTER A CRASH INCREASES THE POSSIBILITY OF A FIRE. INSTALL A CANISTER SHIELD, A REVISED DESIGN DRAIN ROD SHIELD, AND MODIFY FUEL/WATER SEPARATOR MOUNTING BRACKET. VEHICLE DESCRIPTION: VANS, SUPER VANS, SUPER WAGONS AND CLUB WAGONS EQUIPPED WITH 6.9 LITER DIESEL ENGINES. SYSTEM: FUEL/FMVSS 301. 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK ECONOLINE 1984 FORD TRUCK E250 1984 FORD TRUCK E350 1984 FORD TRUCK ECONOLINE 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Vehicle - Moaning/Droaning at 55 to 65 MPH Article No. 85-4-39 MOAN/DRONE (5.0L/5.8L) - 2100 2800 RPM LIGHT TRUCK 1983-85 ECONOLINE, F150-350, BRONCO A moan/drone condition encountered at 55-65 mph may be a 2100-2800 engine rpm-related condition. Diagnosis and servicing will require a good road test followed by servicing of: 1) engine mounting, 2) exhaust hanger, 3) alternator pulley, and 4) alternator/thermactor braces depending on vehicle model and engine combination. 1. Road Test & Service Engine Mountings a. Road test vehicle. The vehicle should be equipped with a portable tachometer and driven at a road speed of 55-65 MPH (engine speed of 2100-2800 RPM). The A/C system should be in the "off" position and the vehicle should be evaluated on a smooth surfaced road or highway. If the road test verifies a "drone/ moan" condition, then the following procedures should be followed: Figure 25 b. On Bronco and F150-350 vehicles, loosen the No. 3 crossmember/rear engine support gussets at the attachment to the crossmember. If the gussets pull away from the crossmember, add shims to the gap. Retighten mounting bolts (install larger bolts if required). Refer to attached Figure 25). c. On model F150-350 (4x2)/E150-350 vehicles, inspect rear engine insulator (mount) for correct usage of Engineering Part E3TA-6D091-A/Service Part E0TZ-6068-B (white color code). Install correct part if required. Inspect mount for correct orientation of "capture strap" which could bind up the mount. With the vehicle on a two-post hoist, neutralize the front and rear engine support insulators (front and rear engine mounts) by loosening the front and rear engine mounts attaching bolts (attaching front mounts to support bracket and the rear mount to the No. 3 crossmember. Lower the vehicle and place safety stands under the front and rear axles. Start the engine and shift the automatic transmission into "drive" and back into "neutral" several times while engine is idling. With manual transmission, load engine by shifting transmission into forward and reverse gears and, with the parking brake partially applied, slip the clutch to load the engine. Raise the vehicle and remove the axle stands. Retorque front and rear engine mount attaching bolts (refer to Section 21-21 of 1983-1984 Light Truck Shop Manual for torque specifications). Lower vehicle and remove from hoist. d. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 2. Double Link Exhaust Hanger Installation - F - 4 x 2 Models Only a. 1980-83 Vehicles Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 3448 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 3449 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 3450 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 3451 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 3452 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 3458 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 3459 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 3460 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 3461 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel/Water Separator: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 3462 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3471 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3472 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3473 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3474 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3475 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3476 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3477 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3478 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3479 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3480 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3481 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3482 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3483 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3484 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3485 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3486 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3487 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3493 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3494 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3495 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3496 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3497 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3498 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3499 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3500 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3501 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3502 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3503 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3504 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3505 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3506 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3507 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3508 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3509 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Idle Speed/Throttle Actuator - Electronic: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle Actuator - Electronic: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Idle Speed/Throttle Actuator - Electronic: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Page 3519 IDLE SPEED CONTROL - FI ENGINES W/ISC. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Page 3520 Idle Speed/Throttle Actuator - Electronic: Locations Attached To Carburetor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > DC Motor Idle Speed Control Actuator Idle Speed/Throttle Actuator - Electronic: Description and Operation DC Motor Idle Speed Control Actuator Fig. 5 DC motor idle speed control actuator Control Actuator The DC motor idle speed control actuator (DC-ISCA), Fig. 5, is mounted to the fuel charging assembly and controls the idle speed including, high cam RPM, anti-diesel shut-off, dashpot and pre-positioning for the next engine start. The DC-ISCA is controlled by the EEC-IV system and includes an integral idle tracking switch (ITS). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > DC Motor Idle Speed Control Actuator > Page 3523 Idle Speed/Throttle Actuator - Electronic: Description and Operation Idle Air Control (IAC) Valve Fig. 1 Air bypass valve assembly The air bypass valve solenoid, Fig. 1, is used to control engine idle speed and is operated by the EEC-IV control module. This valve allows air to pass around the throttle plates to control, cold engine fast idle, no touch start, dashpot, over temperature idle boost and engine idle load correction. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 3524 Idle Speed/Throttle Actuator - Electronic: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect air bypass valve electrical connector. 3. On models with 4-140 engine, remove air cleaner assembly. 4. On all models, remove air bypass valve attaching bolts, then the air bypass valve and gasket. 5. Reverse procedure to install. Torque air bypass valve attaching bolts to 71 - 102 inch lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 3530 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator > Page 3535 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Description and Operation > Page 3536 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations Under I/P Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 3542 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Technical Service Bulletins > Air Intake System - Water Entry Intake Air Duct: Technical Service Bulletins Air Intake System - Water Entry Article No. ^ WATER ENTRY - 2.9L, 5.0L EFI, 6.9L DIESEL 87-2-25 ^ ENGINE - 2.9L, 5.0L EFI, 6.9L DIESEL - WATER ENTRY THROUGH AIR INTAKE SYSTEM LIGHT TRUCK 1983-86 RANGER, BRONCO II, BRONCO, E SERIES, F SERIES ISSUE: Reports have been received of internal damage occuring to 2.9L, 5.0L EFI and 6.9L light truck engines due to water being drawn into the air intake system while the vehicles are being driven in normal wet conditions, such as water splash/spray from vehicles or in shallow water. ACTION: The air cleaner for the 6.9L engine has been changed to correct the condition on 1987 model year vehicles. Prior model year changes are covered in TSB 87-2-26. Improvements to the air inlet systems for the 2.9L and 5.0L EFI engines will occur in the 1988 model year. Because the concern can occur during normal operating conditions, dealers are urged to assure that in-warranty repairs are not denied unless there is evidence of owner misuse. OTHER APPLICABLE ARTICLES: 87-2-26 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3550 Main Relay (Computer/Fuel System): Description and Operation Fig. 12 EEC relay type, system application & relay locations EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine applications. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Locations Fuel Shut-off Solenoid Relay: Locations LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3574 Main Relay (Computer/Fuel System): Description and Operation Fig. 12 EEC relay type, system application & relay locations EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power relays also provide reverse battery protection and increased load handling to improve ignition switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine applications. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, then translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor constantly monitors air temperature entering the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > Tank Selector Relay Fuel Tank Selector Switch: Locations Tank Selector Relay Left Rear Corner Of Engine Compartment (next to fuel cut-off relay). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 > Tank Selector Relay > Page 3583 Fuel Tank Selector Switch: Locations Fuel Tank Selector Switch LH Side Of I/P Near Fuse Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations Under I/P Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 3589 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Description and Operation Throttle Full Close Switch: Description and Operation The idle tracking switch, is a mechanically operated electric switch held open by the throttle linkage when the throttle is closed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 3597 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 3598 OASIS CODES: 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 3599 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3600 THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3601 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box > Page 3604 Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > Page 3605 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect throttle position sensor electrical connector. 3. Scribe a reference mark across edge of sensor and to throttle body to ensure correct position during installation. 4. Remove two sensor attaching screws, then the sensor and gasket. 5. Reverse procedure to install, noting the following: a. Slide the throttle position sensor rotary tangs into position over throttle shaft blade, then rotate sensor clockwise to align scribe marks. b. Torque sensor attaching screws to 11 - 16 inch lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3614 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3615 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3616 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3617 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3618 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3619 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3620 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3621 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3622 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3623 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3624 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3625 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3626 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3627 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3628 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3629 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3630 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3636 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3637 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3638 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3639 Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3640 Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3641 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3642 Figure 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3643 Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3644 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3645 Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3646 Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3647 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3648 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3649 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3650 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3651 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3652 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Full Close Switch > Component Information > Description and Operation Throttle Full Close Switch: Description and Operation The idle tracking switch, is a mechanically operated electric switch held open by the throttle linkage when the throttle is closed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Diagnostic Tips Article No. 85-20-11 SELF-TEST CODE 53 - EEC IV - THROTTLE POSITION SENSOR DIAGNOSTIC TIP FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR LIGHT TRUCK 1985-86 RANGER, BRONCO II, ECONOLINE, F-SERIES CALIBRATION: All with EEC IV WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws. A new design Throttle Position Sensor (TPS) has been released for all 1986 EEC IV applications. The new TPS is designed to eliminate a false Self-Test Code 53. A Code 53 indicates the TPS system has failed at the wide open throttle position (approximately 5.0 volts), The new TPS eliminates false Code 53 by limiting the wide open throttle voltage to 4.75 volts. With the new TPS, Code 53 will only result from a circuit or TPS malfunction. The new Throttle Position Sensors can be used to replace faulty sensors on 1985 vehicles. If the old design service part is used, a false Code 53 may result. PART NUMBER PART NAME CLASS E6DZ-9B989-A Throttle Position Sensor C E6TZ-9B989-C Throttle Position Sensor WC E6DZ-9B989-C Throttle Position Sensor WC E6FZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-A Throttle Position Sensor B E6ZZ-9B989-B Throttle Position Sensor WC E6TZ-9B989-A Throttle Position Sensor C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 3660 Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP Article No. 89-16-4 FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely. ACTION: Refer to one of the following TPS service replacement charts to make sure that the correct service part is installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 3661 OASIS CODES: 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Diagnostic Tips > Page 3662 Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3663 THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3664 Engine View Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout Box > Page 3667 Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > Page 3668 Throttle Position Sensor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect throttle position sensor electrical connector. 3. Scribe a reference mark across edge of sensor and to throttle body to ensure correct position during installation. 4. Remove two sensor attaching screws, then the sensor and gasket. 5. Reverse procedure to install, noting the following: a. Slide the throttle position sensor rotary tangs into position over throttle shaft blade, then rotate sensor clockwise to align scribe marks. b. Torque sensor attaching screws to 11 - 16 inch lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Air Bypass Valve, Turbocharger > Air Bypass Valve Solenoid, Turbocharger > Component Information > Technical Service Bulletins > Customer Interest: > 87533 > Mar > 87 > Exhaust - White or Grayish White Smoke Air Bypass Valve Solenoid: Customer Interest Exhaust - White or Grayish White Smoke Article No. EXHAUST - WHITE OR GRAYISH WHITE SMOKE 87-5-33 5.0L EFI - DURING ENGINE IDLE LIGHT TRUCK 1985-86 E SERIES, F SERIES, BRONCO ISSUE: Vehicles built between 11/01/84 and 07/31/86 may give off a white or grayish white smoke from the exhaust after extended highway driving. This is caused by a thermactor system that does NOT switch to "Dump Mode". ACTION: To correct this, check the thermactor system using the following service diagnostic procedure and install a thermactor bypass valve and/or solenoid as required. 1. Check for kinks in vacuum hose(s) running from the thermactor solenoid to thermactor bypass valve. Refer to TSB 86-9-11 for vacuum hose service procedure. 2. Perform EEC IV quick test. If service code 46 displays, proceed to Step 3. If any other service codes appear, correct as necessary. 3. Refer to Volume H, Section 10 of the Engine/Emission Diagnosis Shop Manual for component location and Section 21 (Pinpoint Test KC) for diagnosis. If the thermactor bypass valve needs to be replaced, replace with bypass valve, E1TZ-9B289-C, and if the thermactor solenoid needs to be replaced, replace solenoid with E6UZ-9D474-A E Series, and E4ZZ- 9D474-E F Series, Bronco. 4. Make sure the vacuum hose(s) are attached securely and are routed to avoid any obstructions. PART NUMBER PART NAME CLASS E1TZ-9B289-C Thermactor - Bypass B Valve E6UZ-9D474-A Thermactor - Solenoid - C E Series E4ZZ-9D474-E Thermactor - Solenoid - B F Series, Bronco OTHER APPLICABLE ARTICLES: 86-7-16, 86-9-11 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870533A TIME: 1.4 Hrs. - F Series, Bronco 1.5 Hrs. - E Series DLR. CODING: Basic Part No. 9B289 - Code: T5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Air Bypass Valve, Turbocharger > Air Bypass Valve Solenoid, Turbocharger > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 87533 > Mar > 87 > Exhaust - White or Grayish White Smoke Air Bypass Valve Solenoid: All Technical Service Bulletins Exhaust - White or Grayish White Smoke Article No. EXHAUST - WHITE OR GRAYISH WHITE SMOKE 87-5-33 5.0L EFI - DURING ENGINE IDLE LIGHT TRUCK 1985-86 E SERIES, F SERIES, BRONCO ISSUE: Vehicles built between 11/01/84 and 07/31/86 may give off a white or grayish white smoke from the exhaust after extended highway driving. This is caused by a thermactor system that does NOT switch to "Dump Mode". ACTION: To correct this, check the thermactor system using the following service diagnostic procedure and install a thermactor bypass valve and/or solenoid as required. 1. Check for kinks in vacuum hose(s) running from the thermactor solenoid to thermactor bypass valve. Refer to TSB 86-9-11 for vacuum hose service procedure. 2. Perform EEC IV quick test. If service code 46 displays, proceed to Step 3. If any other service codes appear, correct as necessary. 3. Refer to Volume H, Section 10 of the Engine/Emission Diagnosis Shop Manual for component location and Section 21 (Pinpoint Test KC) for diagnosis. If the thermactor bypass valve needs to be replaced, replace with bypass valve, E1TZ-9B289-C, and if the thermactor solenoid needs to be replaced, replace solenoid with E6UZ-9D474-A E Series, and E4ZZ- 9D474-E F Series, Bronco. 4. Make sure the vacuum hose(s) are attached securely and are routed to avoid any obstructions. PART NUMBER PART NAME CLASS E1TZ-9B289-C Thermactor - Bypass B Valve E6UZ-9D474-A Thermactor - Solenoid - C E Series E4ZZ-9D474-E Thermactor - Solenoid - B F Series, Bronco OTHER APPLICABLE ARTICLES: 86-7-16, 86-9-11 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870533A TIME: 1.4 Hrs. - F Series, Bronco 1.5 Hrs. - E Series DLR. CODING: Basic Part No. 9B289 - Code: T5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Air Bypass Valve, Turbocharger > Air Bypass Valve Solenoid, Turbocharger > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bypass Valve Solenoid: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Air Bypass Valve, Turbocharger > Air Bypass Valve Solenoid, Turbocharger > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bypass Valve Solenoid: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 3689 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Air Bypass Valve, Turbocharger > Air Bypass Valve Solenoid, Turbocharger > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bypass Valve Solenoid: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 3695 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbo Boost Control Solenoid Valve <--> [Wastegate Solenoid] > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Turbo Boost Control Solenoid Valve: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications Firing Order 1-5-4-2-6-3-7-8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3705 Firing Order: Mechanical Specifications Location On Distributor FIRING ORDER: 1-5-4-2-6-3-7-8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Cylinder Numbering And Distributor Location Location On Distributor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications Ignition Resistor: Specifications BALLAST RESISTOR: Wire Type - Resistance: 1.1 Ohms + or - .05 Ohms Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications > Page 3719 Ignition Resistor: Locations The Ballast Resistor is a wire type and is in-line with the ignition wiring harness located near the steering column. NOTE: Verify vehicle has a ballast resistor by referencing wiring diagram. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3724 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3729 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure Distributor Cap: Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 3735 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 3736 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure Ignition Rotor: Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 3741 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Spark Knock Diagnostic Procedure > Page 3742 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure Hall Effect Sensor: Technical Service Bulletins Distributor Stator - Replacement Procedure Article No. 85-4-21 DISTRIBUTOR UNIVERSAL - ALL - STATOR REPLACEMENT FORD 1983-1985 ESCORT, EXP, TEMPO, CROWN VICTORIA, MUSTANG, THUNDERBIRD, LTD LINCOLN-MERCURY 1983-1985 LYNX, TOPAZ, CAPRI, COUGAR, MARQUIS, GRAND MARQUIS, LINCOLN, CONTINENTAL, MARK VII LIGHT TRUCK 1984-1985 BRONCO II, 1983-1985 RANGER, 1985 F-100 THRU F-250, 1984-1985 ECONOLINE The stator assembly (-12A112-) is now a serviceable component for the above vehicles. The procedures to be used when servicing the stator assembly are as follows: 1.6L EFI and 1.6L EFI T/C DISTRIBUTOR W/TFI STATOR ASSEMBLY REPLACEMENT Removal 1. Using a screwdriver, remove the distributor cap and position it and the attached wires aside so as not to interfere with work area. 2. Disconnect the TFI module from the harness. 3. Remove the distributor from the engine block. 4. Remove the rotor. 5. Remove the drive coupling spring with a small screwdriver or ice pick. Take care not to damage the drive coupling or spring. 6. a. Using an air hose, blow dirt and oil from the drive end of the distributor. b. Put a small paint dot on the drive coupling and the shaft to note orientation for re-assembly. Figure 31 - Distributor Support Tool c. Place the distributor support tool (Figure 31) in a vise and tighten or open the vise jaws wide enough to let pin drop out of the coupling but not so wide that the coupling is not supported. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3747 d. Line-up the drive pin with the slot in the base. 7. With someone holding the distributor steady on the support tool or vise, use a 5/32 inch diameter drift and hammer to drive the pin out of the shaft. 8. Remove the distributor from the fixture. Remove the drive coupling from the fixture and place aside for re-assembly. 9. Before removing the shaft from the base, check for burrs on the end of the shaft and especially around the drive pin hole. If burrs are present, polish the shaft with emery paper and wipe clean before removing the shaft from the base to prevent damage to the lip seal and bushing in the base. 10. After assuring that there are no burrs, remove shaft assembly by gently pulling up on the shaft plate. 11. Remove the two screws holding the module to the base. 12. Remove the module. Wipe grease from the base and module, keeping surfaces free of dirt. 13. Remove the octane rod retaining screw. 14. Remove the octane rod assembly. 15. Remove the two screws retaining the stator connector in the bowl of the distributor. (Retain the screws for re-assembly.) 16. Remove the stator assembly from the top of the bowl, by gently lifting up. 17. Inspect the base bushing for wear or signs of excess heat concentration, replace the complete distributor assembly if damaged. 18. Inspect the shaft oil seal for tears or cuts; replace the complete distributor assembly if oil seal is damaged. 19. Carefully check the spring retainer that holds the shaft oil seal against the shaft - it must be present and have no kinks or breaks. Replace spring if necessary. 20. Inspect the base "O" ring for cuts or damage and replace the "O" ring if necessary. 21. Inspect base casting for cracks and wear. Replace complete distributor assembly if damage is found. Re-assembly and Installation 1. Place the stator over the bushing and press down to seat. 2. Place the stator connector in position - tab should fit in the notch on the base and the fastening eyelets should be aligned with their screw holes. 3. Position the wires away from moving parts. 4. Reinstall the two stator screws and torque to specification (25-35 in.lbs.). 5. With the seal on the octane rod, insert in holes. Reinstall the octane rod through the base octane rod hole. 6. Place the end of the octane rod onto the same post as the original stator only (one post should easily fit in the octane rod hole). 7. Reinstall the octane rod screw and torque to specification (25-35 in.lbs.). 8. Wipe the back of the module and the distributor module mounting face free of all dirt. 9. Apply grease (No. WA10) to back of the module and spread evenly (thin, even coverage). 10. Turn the distributor base upside down so that the stator connector is in full view. 11. Insert the module, being sure that the three module pins are inserted into the stator connector. 12. Fully seat the module into the connector and against the base. 13. Reinstall the module screws and torque to specification (25-35 in.lbs.). 14. Apply a light coat of M2C162A oil to the distributor shaft below the armature. NOTE: Do not over-lubricate. 15. Insert the shaft assembly through the base bushing. 16. Place the drive coupling over the shaft and line up the paint dots that were made during disassembly. Start the pin into the drive coupling and shaft. 17. With someone holding the distributor steady on the support tool or vise, drive the pin into the shaft until the end of the pin is flush with the step in the drive coupling. 18. Check for free movement of the drive coupling on the pin and verify that the pin does not extend beyond the step in the coupling in either direction. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3748 19. Remove the distributor from the fixture and check for free rotation. 20. Install the drive coupling spring in the groove on the drive coupling. 21. Install the distributor assembly in the engine. 22. Install the distributor cap and rotor. 23. Install the TFI module connector. UNIVERSAL DISTRIBUTOR W/EEC (OTHER THAN 1.6L) STATOR ASSEMBLY REPLACEMENT NOTE: Do not attempt to replace the stator without an arbor press. Removal 1. Using a screwdriver, remove the distributor cap, position the cap and wires aside so as not to interfere with the work area. - Remove TFI module connector. 2. Remove distributor from block per the distributor removal procedure. 3. Remove rotor. 4. Remove the two screws holding the TFI module to the base. 5. Remove the module, wipe the grease from the base and module, keeping the surfaces free of dirt. 6. If the distributor uses the push-on rotor, remove the two screws holding the armature and remove the armature. NOTE: Hold the gear to loosen the armature screws, do not hold the armature. 7. To ease re-assembly, mark with a felt tip pen, the armature, gear and collar if present (Refer to the following chart.) to note orientation. 8. Remove and discard pins in gear and collar if present (Refer to chart.). Figure 32 - Bearing Removal Tool 9. Invert the distributor and place in the Axle Bearing/Seal Plate (Tool D84L-950-A) and press off the gear using the Bearing Removal Tool (T75L-1165-B) as shown in Figure 32. 10. Deburr and polish shaft with emery paper and wipe such that the shaft slides out freely from distributor base. 11. Remove shaft assembly. 12. Remove thrust washer from distributor shaft and retain. 13. Remove octane rod retaining screw and retain. 14. Remove octane rod assembly and retain. GEAR GEAR THRUST ROLL PIN COLLAR ENGINE GEAR PIN WASHER EXTRUSION COLLAR PIN 2.3L HSC 67555-S FLUSH Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3749 2.3L OHC 67555-S FLUSH 2.8L 67575-S FLUSH 3.8L 67555-S FLUSH X 67555-S 4.9L 67775-S2 X EXTRUDE EVENLY, BOTH SIDES 5.0L 67555-S FLUSH X 67555-S 6.1L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 7.0L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 7.5L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 15. Remove two stator assembly screws and retain. 16. Remove stator assembly from top of bowl. 17. Inspect base bushing for wear or signs of excess heat concentration, replace complete distributor assembly if damaged. 18. Inspect base "O" ring for cuts or damage and replace "O" ring if necessary. 19. Inspect base for cracks and wear. Replace complete distributor assembly if damage is found. Re-assembly and Installation 1. Place the stator assembly over the bushing and press down to seat. 2. Place the stator connector in position - tab should fit in notch on base and fastening eyelets aligned with screw holes. 3. Position wires away from moving parts. 4. Install the two stator screws and torque to specification (25-35 in.lbs.). 5. Reinstall the octane rod, inserting rod through the base hole. 6. Place end of octane rod onto the same post as the original stator. Only one post should easily fit in rod hole. 7. Firmly seat octane rod seal into housing. 8. Reinstall the octane rod screw and torque to specification (25-35 in./lbs.). 9. If required, reinstall the thrust washer on top of the bushing. 10. Apply a light coat of ESF-M2C70-A to the distributor shaft below the armature. 11. Insert the shaft through the base bushing. 12. Place the collar, if required, over the shaft and line up mark on armature and collar to aid alignment with original drill hole. Use a drift punch to assure proper alignment. NOTE: Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, the collar may be 180 degrees out of alignment on the shaft. Rotate the collar on the shaft one half rotation and recheck. 13. Insert new roll pin (Part No. 67555-S) through collar and shaft. Pin should be flush with both sides of collar when seated. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3750 Figure 33 - Push On Rotor Figure 34 - Screw Down Rotor 14. If the distributor uses a push-on rotor, place a 1/2 inch deep well socket over the shaft (Figure 33), invert and place on arbor plate. 14a. If the distributor uses a screw-down rotor, invert and place on arbor plate (Figure 34). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3751 Figure 35 - Press Gear 15. Place the distributor gear on the shaft and line up the mark on the armature and gear. NOTE: The hole in the shaft and gear must be lined up as accurately as possible to assure ease of roll pin insertion. 16. Place a 5/8 inch deep well socket over the shaft and gear (Figure 35) and press gear to align with original drill hole. NOTE: If the gear holes do not align, the gear must be removed and repressed on. A drift punch will not align the holes. As in the collar, the holes should align. 17. Insert new roll pin (Refer to chart following Step 7 in the Removal Procedure) through gear and shaft. Pin should have proper extrusion, as referenced in same chart. 18. If the armature was removed, replace and torque screws to 25-35 in.lbs. 19. Check distributor for free movement over full rotation of shaft. NOTE: If the armature hits the stator; replace the entire distributor. 20. Wipe back of module and distributor module mounting face free of all dirt. 21. Apply grease (No. WA10) to the back of the module and spread evenly (thin, even coverage). 22. Turn the distributor base upside down such that the stator connector is in full view. 23. Insert the module and watch that the three module pins are inserted into the stator connector. Fully seat the module into the connector and against base. 24. Reinstall two module screws and torque to specification (25-35 in.lbs.). 25. Reinstall the distributor into block per distributor replacement procedure. 26. Connect TFI module to wiring harness. 27. Replace rotor and torque screws to specification. 28. Replace cap and torque screws to specification. 29. Retime engine. PART NUMBER PART NAME CLASS 67555-S Pin BS 67775-S2 Pin RS E3ZZ-12A112-C Stator A OTHER APPLICABLE ARTICLES: None Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3752 WARRANTY STATUS: "INFORMATION ONLY" OPERATION: STATOR REPLACE 12112D1 TIME: 1.6L Engine 0.6 HR. All Others 0.5 HR. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3753 Hall Effect Sensor: Technical Service Bulletins Engine - No Start/Idles Rough/Knock When Cold Article No. 85-7-11 (Supercedes Article No. 85-4-20) 04/04/85 NO START - ALL EEC IV IDLE ROUGH - ALL EEC IV - COLD SPARK KNOCK - ALL EEC IV COLD FORD: 1984-85 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, LTD, CROWN VICTORIA LINCOLN-MERCURY: 1984-85 LYNX, LN7 TOPAZ, CAPRI, COUGAR, MARQUIS, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK: 1984-85 BRONCO II; 1983, 84, 85 RANGER; 1984-85 F100 THRU F-250; 1984-85 ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3754 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3755 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3756 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3757 This article is being republished to revise Test 5. The above concerns can be caused by the distributor Hall Effect sensor. When the above concerns occur only at cold temperatures and the engine starts and runs satisfactorily when warm, use the first diagnostic procedure. If the concern is no start, use the second procedure. If a T.F.I. is removed from the distributor and the stator connector is soft or mushy, replace the stator. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" TFI Module Side of the SPOUT Connector Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 3758 Terminal Voltage Measurement Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 3759 Hall Effect Sensor: Description and Operation Profile Ignition Pickup The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA. PIP Sensor COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator, Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the output is high. When the signal is high the output is low. This output then goes to the Schmitt trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 3760 PIP Signal Operation OPERATION The output signal to the Darlington amplifier is high when the window (on the armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington amplifier (switch on). Hall Effect Sensor In other words when one of the windows or openings is in the gap between the Hall device and the permanent magnet, the field stays strong and the voltage is high since the magnetic path is complete from the magnet, through the Hall device, and back to the magnet. In this case the switch is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the TFI module if the SPOUT signal from the ECA is lost. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 3761 Signature PIP SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature profile ignition pickup signal. The regular type armature used for the PIP signal has the same size tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors. This system is used on cars and trucks where the ECA needs to know when to pulse certain injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the No. 1 cylinder needs to be supplied with fuel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 3766 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 3767 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 3768 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Ignition System - Diagnostics Manual Correction > Page 3769 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 3770 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 872018 > Oct > 87 > Engine/Ignition - No Start Condition Ignition Coil: Customer Interest Engine/Ignition - No Start Condition NO START - EEC IV - "E" COIL Article No. 87-20-18 FORD: 1983-86 LTD 1983-87 ESCORT, EXP, MUSTANG, THUNDERBIRD, CROWN VICTORIA 1984-87 TEMPO 1986-87 TAURUS LINCOLN-MERCURY: 1983 LN7 1983-86 MARQUIS 1983-87 LYNX, COUGAR, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN TOWN CAR 1984-87 TOPAZ 1986-87 SABLE LIGHT TRUCK: 1983-87 RANGER, E-SERIES, F-SERIES, BRONCO 1984-87 BRONCO II 1986-87 AEROSTAR This article is being republished in its entirety to expand the model year coverage. ISSUE: The primary winding of the E-core ignition coil may be damaged if the wire harness containing the tachometer circuit has a short to ground. ACTION: Before replacing the E-core ignition coil, perform the following diagnostic procedure. 1. Turn ignition to "ON" position. 2. Measure and record battery voltage. Figure 50 3. Measure and record voltage between negative terminal and coil and battery ground post as shown, Figure 50. 4. If the differencce in readings is greater than 1.0 volt, check tachometer circuit for a potential short to ground. 5. If a short is present, make necessary wire harness repair. 6. Replace ignition coil as required. OTHER APPLICABLE ARTICLES: Supersedes 84-14-18, 84-14-18-S, 85-16-13, 86-2-21 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 8628 > Jan > 86 > Ignition Coil - Stumbles/Stalls/Noise In Radio Ignition Coil: Customer Interest Ignition Coil - Stumbles/Stalls/Noise In Radio Article No. 86-2-8 STUMBLES, STALLS - EEC - E-CORE IGNITION COIL NOISE IN RADIO - EEC - E-CORE IGNITION COIL CLOCK ERRATIC PERFORMANCE - EEC - E-CORE IGNITION COIL FORD 1983-86 ALL LINCOLN-MERCURY 1983-86 ALL LIGHT TRUCK 1983-86 ALL CALIBRATIONS: All with E-Core Ignition Coils This article is being reprinted to include 1986 vehicle applications. Stumbles, stals, poor performance, ignition noise in the radio, erratic electronic clock performance or erratic service codes during vehicle Quick Test can be caused by high voltage arc in the E-core ignition coil. Figure 8 The arc is a result of an open or high resistance in the coil secondary winding. The arc generates high fre quency noise in the vehicle electrical system. This noise can disrupt the EEC syste and invalid service codes such as 22,10,20,30, or 40 BCT. This condition can be checked as follows: 1. Place the ignition switch in the OFF position. 2. Disconnect the E-core ignition coil primary and secondary leads. 3. Using Rotunda digital volt-ohmmeter 007-00001, measure the resistance between the primary (+) terminal and the high voltage secondary terminal. (Figure 8). 4. If the resistance is greater than 14,000 ohms, replace the coil. 5. Reconnect the high voltage secondary lead and confirm that the protective boot is fully seated. 6. Reconnect the coil primary lead. 7. Verify that the reported condition has been cor rected. PART NUMBER PART NAME CLASS E3FZ-12029-A Ignition Coil A OTHER APPLICABLE ARTICLES: 84-23-1, 85-13-2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 8628 > Jan > 86 > Ignition Coil - Stumbles/Stalls/Noise In Radio > Page 3783 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP12029B84 TIME: 0.5 Hr. - F150-350, Bronco 0.6 Hr. - Econoline 0.3 Hr. - All Other DLR. CODING: Basic Part No. 12029 - Code: 28 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Coil: Customer Interest Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 3788 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 3789 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction Ignition Coil: All Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 3795 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 3796 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 3797 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 3798 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 872018 > Oct > 87 > Engine/Ignition - No Start Condition Ignition Coil: All Technical Service Bulletins Engine/Ignition - No Start Condition NO START - EEC IV - "E" COIL Article No. 87-20-18 FORD: 1983-86 LTD 1983-87 ESCORT, EXP, MUSTANG, THUNDERBIRD, CROWN VICTORIA 1984-87 TEMPO 1986-87 TAURUS LINCOLN-MERCURY: 1983 LN7 1983-86 MARQUIS 1983-87 LYNX, COUGAR, GRAND MARQUIS, MARK VII, CONTINENTAL, LINCOLN TOWN CAR 1984-87 TOPAZ 1986-87 SABLE LIGHT TRUCK: 1983-87 RANGER, E-SERIES, F-SERIES, BRONCO 1984-87 BRONCO II 1986-87 AEROSTAR This article is being republished in its entirety to expand the model year coverage. ISSUE: The primary winding of the E-core ignition coil may be damaged if the wire harness containing the tachometer circuit has a short to ground. ACTION: Before replacing the E-core ignition coil, perform the following diagnostic procedure. 1. Turn ignition to "ON" position. 2. Measure and record battery voltage. Figure 50 3. Measure and record voltage between negative terminal and coil and battery ground post as shown, Figure 50. 4. If the differencce in readings is greater than 1.0 volt, check tachometer circuit for a potential short to ground. 5. If a short is present, make necessary wire harness repair. 6. Replace ignition coil as required. OTHER APPLICABLE ARTICLES: Supersedes 84-14-18, 84-14-18-S, 85-16-13, 86-2-21 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 8628 > Jan > 86 > Ignition Coil - Stumbles/Stalls/Noise In Radio Ignition Coil: All Technical Service Bulletins Ignition Coil - Stumbles/Stalls/Noise In Radio Article No. 86-2-8 STUMBLES, STALLS - EEC - E-CORE IGNITION COIL NOISE IN RADIO - EEC - E-CORE IGNITION COIL CLOCK ERRATIC PERFORMANCE - EEC - E-CORE IGNITION COIL FORD 1983-86 ALL LINCOLN-MERCURY 1983-86 ALL LIGHT TRUCK 1983-86 ALL CALIBRATIONS: All with E-Core Ignition Coils This article is being reprinted to include 1986 vehicle applications. Stumbles, stals, poor performance, ignition noise in the radio, erratic electronic clock performance or erratic service codes during vehicle Quick Test can be caused by high voltage arc in the E-core ignition coil. Figure 8 The arc is a result of an open or high resistance in the coil secondary winding. The arc generates high fre quency noise in the vehicle electrical system. This noise can disrupt the EEC syste and invalid service codes such as 22,10,20,30, or 40 BCT. This condition can be checked as follows: 1. Place the ignition switch in the OFF position. 2. Disconnect the E-core ignition coil primary and secondary leads. 3. Using Rotunda digital volt-ohmmeter 007-00001, measure the resistance between the primary (+) terminal and the high voltage secondary terminal. (Figure 8). 4. If the resistance is greater than 14,000 ohms, replace the coil. 5. Reconnect the high voltage secondary lead and confirm that the protective boot is fully seated. 6. Reconnect the coil primary lead. 7. Verify that the reported condition has been cor rected. PART NUMBER PART NAME CLASS E3FZ-12029-A Ignition Coil A OTHER APPLICABLE ARTICLES: 84-23-1, 85-13-2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 8628 > Jan > 86 > Ignition Coil - Stumbles/Stalls/Noise In Radio > Page 3807 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP12029B84 TIME: 0.5 Hr. - F150-350, Bronco 0.6 Hr. - Econoline 0.3 Hr. - All Other DLR. CODING: Basic Part No. 12029 - Code: 28 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Coil: All Technical Service Bulletins Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 3812 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 3813 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 84228 > Oct > 84 > Ignition - Coil Durability/Radio Frequency Interference Ignition Coil: All 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction Ignition Coil: All Technical Service Bulletins Ignition System - Diagnostics Manual Correction Article No. 89-5A-4 EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND CROWN VICTORIA LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ, GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES 1986-88 AEROSTAR ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989 Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service information directs technicians to use a substitute coil instead of a resistance test. ACTION: Refer to this TSB for revised ignition coil and secondary wire test information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 Ignition Systems, Timing Procedures and Diagnostics 13-51 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 3823 Ignition Coil and Secondary Wire TFI-IV And TFI With CCD Part 2 Test 7 1989 13-52 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 3824 EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2 Test 8 1989 Ignition Systems, Timing Procedures and Diagnostics 13-65 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 3825 Ignition Coil And Secondary Wire TFI-IV Closed Bowl Distributor Part 2 Test 8 1989 13-66 Ignition Systems, Timing Procedures and Diagnostics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual Correction > Page 3826 EEC-IV - Wiring TFI-IV Closed Bowl Distributor Part 2 Test 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Coil: > 84228 > Oct > 84 > Ignition - Coil Durability/Radio Frequency Interference Ignition Coil: All 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3831 Ignition Coil: Specifications Winding Resistance (ohms at 75 degrees F or 24 degrees C) 1982-88 w/TFI (EEC IV): Primary, 0.3-1.0; Secondary, 8000-11,500. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 3832 Component Locations - RH Side Of Engine TFI-IV Ignition Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 861125 > Jun > 86 > Engine - Cranks/No Start/Stalls At Idle Ignition Control Module: Customer Interest Engine - Cranks/No Start/Stalls At Idle Article No. 86-11-25 STALL IDLE ALL EEC IV WITH TFI NO START - ENGINE CRANKS ALL EEC IV WITH TFI FORD 1984-86 ALL WITH EEC IV LINCOLN-MERCURY 1984-86 ALL WITH EEC IV Low mileage vehicles may experience an intermittent no start or stall at idle. This concern can be experienced on all 1986 production vehicles or on vehicles that have had a TFI IV Ignition Module Service replaced using part number E3EF-12A297-AlA. If an internal short circuit occurs in some recently manufactured TFI IV Ignition Modules (part number suffix A1A), the Hall sensor may become shorted to ground. At the moment of short, the EEC processor will not receive a PIP signal and the vehicle will not start or may stall at idle. The concern has been isolated to TFIIV Ignition Modules with a part number that contains the A1A suffix and a manufacturing date code of 5FOl (85 June 01) through 6D17 (86 April 17). The date code is heat stamped on the module connector shroud. 1. Follow normal Shop Manual, Volume H service procedures. NOTE: This concern can be an intermittent condition and Intermittent Diagnostic Procedures may have to be followed. 2. If replacement of the TFI IV Ignition Module is indicated, assure that service replacement part contains a part number with a suffix of A2A or one with a suffix of A1A and a manufacturing date code before 5FOl or after 6D17. PART NUMBER PART NAME CLASS E43Z-12A297-A TFI Ignition Module A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 1265OD15 TIME: 1.0 Hr. - 1.9L EFI 0.9 Hr. -All others DLR. CODING: Basic Part No. 12A297 - Code: N2, N9, Pl Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: Customer Interest Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 3849 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 3850 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine Spark Knock Diagnostic Procedure Ignition Control Module: All Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine Spark Knock Diagnostic Procedure > Page 3856 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine Spark Knock Diagnostic Procedure > Page 3857 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3862 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3863 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3864 TFI-IV Part 2 Test 3 Stator - TFI Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3865 TFI-IV Part 2 Test 4 & 5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3866 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3867 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3868 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3869 TFI-IV Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3870 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3871 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3872 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3873 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3874 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3875 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3876 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3877 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3878 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3879 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3880 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3881 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3882 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3883 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3884 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine Stalling and/or A No Start Condition Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 861125 > Jun > 86 > Engine Cranks/No Start/Stalls At Idle Ignition Control Module: All Technical Service Bulletins Engine - Cranks/No Start/Stalls At Idle Article No. 86-11-25 STALL IDLE ALL EEC IV WITH TFI NO START - ENGINE CRANKS ALL EEC IV WITH TFI FORD 1984-86 ALL WITH EEC IV LINCOLN-MERCURY 1984-86 ALL WITH EEC IV Low mileage vehicles may experience an intermittent no start or stall at idle. This concern can be experienced on all 1986 production vehicles or on vehicles that have had a TFI IV Ignition Module Service replaced using part number E3EF-12A297-AlA. If an internal short circuit occurs in some recently manufactured TFI IV Ignition Modules (part number suffix A1A), the Hall sensor may become shorted to ground. At the moment of short, the EEC processor will not receive a PIP signal and the vehicle will not start or may stall at idle. The concern has been isolated to TFIIV Ignition Modules with a part number that contains the A1A suffix and a manufacturing date code of 5FOl (85 June 01) through 6D17 (86 April 17). The date code is heat stamped on the module connector shroud. 1. Follow normal Shop Manual, Volume H service procedures. NOTE: This concern can be an intermittent condition and Intermittent Diagnostic Procedures may have to be followed. 2. If replacement of the TFI IV Ignition Module is indicated, assure that service replacement part contains a part number with a suffix of A2A or one with a suffix of A1A and a manufacturing date code before 5FOl or after 6D17. PART NUMBER PART NAME CLASS E43Z-12A297-A TFI Ignition Module A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 1265OD15 TIME: 1.0 Hr. - 1.9L EFI 0.9 Hr. -All others DLR. CODING: Basic Part No. 12A297 - Code: N2, N9, Pl Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: All Technical Service Bulletins Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 3901 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 3902 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Ignition Control Module: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure Ignition Control Module: All Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 3912 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 3913 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3918 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3919 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3920 TFI-IV Part 2 Test 3 Stator - TFI Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3921 TFI-IV Part 2 Test 4 & 5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3922 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3923 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3924 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3925 TFI-IV Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3926 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3927 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3928 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3929 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3930 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3931 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3932 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3933 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3934 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3935 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3936 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3937 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3938 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3939 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3940 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Ignition Control Module: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3949 Component Locations - RH Side Of Engine TFI-IV Ignition Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3950 Ignition Control Module: Description and Operation Thick Film Ignition Module The TFI IV ignition module, Fig. 14, has six connector pins at the wiring harness that supplies the following signals: Run Crank (start) Tach (coil) PIP (crankshaft position to ECA) Spark output (SPOUT from ECA) Internal ground from the ECA to the distributor Ignition System The TFI IV module supplies the spark to the distributor through the ignition coil and calculates the duration. It receives its control signal from the ECA (SPOUT) Fig. 29. NOTE: Some later models use a remote module (Closed Bowl Distributors/CBD). It is located in the engine compartment (Refer to "COMPONENT LOCATIONS"). The operation is essentially the same with the exception of the CBD has a wiring harness between the ignition module and the distributor. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3951 Ignition Control Module: Service and Repair Open Bowl Distributor 1. Remove distributor cap and adapter. Position cap and wires aside. 2. Disconnect TFI wiring. 3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type hold-down bolt, if equipped. 4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2. 5. Pull right side of module down distributor mounting flange and then back up to disengage module terminals from connector in distributor base. Module may then be pulled toward flange and away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI module toward distributor flange, as pins at distributor/module connector will break otherwise. 6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease D7AZ-19A331-A, or equivalent. 7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly toward distributor bowl and securely engage 3 distributor connector pins. 8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs. 9. Install distributor on engine. 10. Install distributor cap and adapter. 11. Connect TFI wiring. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3952 12. Check and, if necessary adjust engine timing according to decal. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications DISTRIBUTOR PICKUP Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87610 > Mar > 87 > Engine Stalling and/or A No Start Condition Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 861125 > Jun > 86 > Engine - Cranks/No Start/Stalls At Idle Ignition Control Module: Customer Interest Engine - Cranks/No Start/Stalls At Idle Article No. 86-11-25 STALL IDLE ALL EEC IV WITH TFI NO START - ENGINE CRANKS ALL EEC IV WITH TFI FORD 1984-86 ALL WITH EEC IV LINCOLN-MERCURY 1984-86 ALL WITH EEC IV Low mileage vehicles may experience an intermittent no start or stall at idle. This concern can be experienced on all 1986 production vehicles or on vehicles that have had a TFI IV Ignition Module Service replaced using part number E3EF-12A297-AlA. If an internal short circuit occurs in some recently manufactured TFI IV Ignition Modules (part number suffix A1A), the Hall sensor may become shorted to ground. At the moment of short, the EEC processor will not receive a PIP signal and the vehicle will not start or may stall at idle. The concern has been isolated to TFIIV Ignition Modules with a part number that contains the A1A suffix and a manufacturing date code of 5FOl (85 June 01) through 6D17 (86 April 17). The date code is heat stamped on the module connector shroud. 1. Follow normal Shop Manual, Volume H service procedures. NOTE: This concern can be an intermittent condition and Intermittent Diagnostic Procedures may have to be followed. 2. If replacement of the TFI IV Ignition Module is indicated, assure that service replacement part contains a part number with a suffix of A2A or one with a suffix of A1A and a manufacturing date code before 5FOl or after 6D17. PART NUMBER PART NAME CLASS E43Z-12A297-A TFI Ignition Module A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 1265OD15 TIME: 1.0 Hr. - 1.9L EFI 0.9 Hr. -All others DLR. CODING: Basic Part No. 12A297 - Code: N2, N9, Pl Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: Customer Interest Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 3979 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 3980 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure Ignition Control Module: All Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 3986 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 3987 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3992 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3993 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3994 TFI-IV Part 2 Test 3 Stator - TFI Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3995 TFI-IV Part 2 Test 4 & 5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3996 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3997 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3998 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 3999 TFI-IV Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4000 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4001 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4002 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4003 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4004 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4005 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4006 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4007 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4008 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4009 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4010 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4011 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4012 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4013 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4014 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start Condition ^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No. EEC IV VEHICLES 87-6-10 ^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES FORD 1984-87 ALL LINCOLN-MERCURY 1984-87 ALL MERKUR 1985-87 XR4Ti LIGHT TRUCK 1984-87 ALL ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI module housing. This condition will result in a service code 14. ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and prevent further concerns. NOTE: The distributor does not have to be removed to perform this repair. 1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior, (mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures and do not perform Steps 2 and 3. 2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper towel. 3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A). 4. Clear service code 14 from memory. PART NUMBER PART NAME CLASS D7AZ-19A331-A Silicone Grease AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 861125 > Jun > 86 > Engine - Cranks/No Start/Stalls At Idle Ignition Control Module: All Technical Service Bulletins Engine - Cranks/No Start/Stalls At Idle Article No. 86-11-25 STALL IDLE ALL EEC IV WITH TFI NO START - ENGINE CRANKS ALL EEC IV WITH TFI FORD 1984-86 ALL WITH EEC IV LINCOLN-MERCURY 1984-86 ALL WITH EEC IV Low mileage vehicles may experience an intermittent no start or stall at idle. This concern can be experienced on all 1986 production vehicles or on vehicles that have had a TFI IV Ignition Module Service replaced using part number E3EF-12A297-AlA. If an internal short circuit occurs in some recently manufactured TFI IV Ignition Modules (part number suffix A1A), the Hall sensor may become shorted to ground. At the moment of short, the EEC processor will not receive a PIP signal and the vehicle will not start or may stall at idle. The concern has been isolated to TFIIV Ignition Modules with a part number that contains the A1A suffix and a manufacturing date code of 5FOl (85 June 01) through 6D17 (86 April 17). The date code is heat stamped on the module connector shroud. 1. Follow normal Shop Manual, Volume H service procedures. NOTE: This concern can be an intermittent condition and Intermittent Diagnostic Procedures may have to be followed. 2. If replacement of the TFI IV Ignition Module is indicated, assure that service replacement part contains a part number with a suffix of A2A or one with a suffix of A1A and a manufacturing date code before 5FOl or after 6D17. PART NUMBER PART NAME CLASS E43Z-12A297-A TFI Ignition Module A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 1265OD15 TIME: 1.0 Hr. - 1.9L EFI 0.9 Hr. -All others DLR. CODING: Basic Part No. 12A297 - Code: N2, N9, Pl Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark Ignition Control Module: All Technical Service Bulletins Ignition System - Weak/No Spark Article No. 86-2-20 IGNITION SYSTEM - TFI - WEAK OR NO SPARK - DIAGNOSTIC TIP FORD 1982-86 ESCORT, EXP; 1983-86 THUNDERBIRD, LTD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 COUGAR, MERCURY, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, RANGER, BRONCO; 1984-86 BRONCO II; 1986 AEROSTAR CALIBRATIONS: All with TFI Systems If the TFI module fails and causes a short to ground, the primary winding of the ignition coil can be damaged. The TFI diagnostic procedure published in the Shop Manual will not identify this condition. When servicing a weak or no spark condition, perform the following: 1. Check for spark using the procedures found in the Manual Information, Computerized Engine, Quick Test Section, Test 1. 2. If there is no spark, test the coil primary resistance using Rotunda digital volt-ohmmeter 007-00001, as shown. 3. If the coil primary resistance is O.K., continue with the diagnostic procedure in Test 1. 4. If the coil primary resistance is not O.K., replace the coil and recheck for weak or no spark. If the spark is now O.K., the problem is resolved. 5. If the spark is still NOT O.K., continue with normal diagnostic procedure in Test 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Wiring Harness TFI-IV Part 2 Test 5 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. 2. Disconnect wire at S terminal of starter relay. 3. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 4. Measure battery voltage. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4031 5. Following table below, measure connector terminal voltage by attaching VOM to small straight pin inserted into connector terminal and turning ignition switch to position shown. CAUTION: Do not allow straight pin to contact electrical ground. CONNECTOR IGNITION SWITCH TERMINAL WIRE/CIRCUIT TEST POSITION #2 TO IGNITION RUN COIL (-) TERMINAL #3 RUN CIRCUIT RUN AND START #4 START CIRCUIT START 6. Turn ignition switch to Off position. 7. Remove straight pin. 8. Reconnect wire to S terminal of starter relay. TEST RESULT TEST RESOLUTION 90 percent of ^ Test result OK. battery ^ Go to Part 2, Test 6. voltage minimum Less than 90 ^ Inspect for faults in wiring percent of harness and connectors. battery ^ Refer to vehicle wiring voltage diagram for appropriate circuit. ^ Damaged or worn ignition switch, Refer to Shop Manual, Group 33. Primary Circuit Continuity TFI-IV Part 2 Test 8 TEST EQUIPMENT: VOM, STRAIGHT PIN TEST PROCEDURE 1. Separate wiring harness connector from ignition module. Inspect for dirt, corrosion, and damage. NOTE: PUSH connector tabs to separate. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 86220 > Jan > 86 > Ignition System - Weak/No Spark > Page 4032 2. Attach negative (-) VOM, Rotunda Number 007-00001, lead to distributor base. 3. Measure battery voltage. 4. Attach VOM to small straight pin inserted into connector terminal No. 2. CAUTION: Do not allow straight pin to contact electrical ground. 5. Turn ignition switch to Run position and measure terminal No. 2 voltage. 6. Turn ignition switch to Off position. 7. Remove straight pin. TEST RESULT TEST RESOLUTION 90 percent of ^ Go to Part 2, Test 5. battery voltage minimum Less than 90 ^ Go to Part 2, Test 9. percent of battery voltage Ignition Coil Primary Resistance TFI-IV Part 2 Test 3 TEST EQUIPMENT: VOM TEST PROCEDURE 1. Turn ignition switch to Off. 2. Disconnect ignition coil connector. Inspect for dirt, corrosion, and damage. 3. Measure resistance from positive (+) to negative (-) terminal of ignition coil, using Rotunda digital volt-ohmmeter 007-00001. TEST RESULT TEST RESOLUTION 0.3 to 1.0 ^ Test result OK. ohm ^ Go to Test 4. Less than ^ Replace ignition coil. 0.3 ohm or greater than 1.0 ohm Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Ignition Control Module: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure Ignition Control Module: All Technical Service Bulletins Engine - Spark Knock Diagnostic Procedure Article No. 93-13-10 06/23/93 SPARK KNOCK - SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE - THICK FILM IGNITION SYSTEM (TFI) - 1985-93 VEHICLES WITH 5.0L EFI ENGINES AND 1988-93 5.8L EFI ENGINES LIGHT TRUCK: 1985-93 BRONCO, ECONOLINE, F-150-350 SERIES ISSUE: Spark knock may be caused by variability in ignition PIP (Profile Ignition Pick-up) output due to a combination of engine torsional vibrations and distributor electrical characteristics. A spark advance spike is generated which repeats every eight firings. ACTION: Perform the following Service Bay Diagnostic System procedure and, if necessary, replace the distributor. NOTE: THE FOLLOWING SBDS PROCEDURE MUST BE USED TO VERIFY IF THE SPECIFIED CONDITION EXISTS ON A GIVEN EFI/TFI 5.0L/5.8L ENGINE. DISTRIBUTORS ON ENGINES THAT HAVE A DETONATION CONCERN AND THAT DO NOT PASS THE SBDS TEST MUST BE RETURNED THROUGH WARRANTY WITH A "BEFORE AND AFTER" PRINTOUT OF THE SBDS IGNITION GRAPH (WITH THE SPIKING CLEARLY SHOWN) TO QUALIFY FOR REIMBURSEMENT. SERVICE BAY DIAGNOSTIC SYSTEM PROCEDURE 1. Use SBDS 60 pin roadtest monitor/record. Select parameters PIP and Spout. 2. Start the warm engine and idle for at least two (2) minutes to allow EEC IV to learn and correct for normal PIP variance. a. Record data using PVA pendant. b. Store the data in a buffer. 3. Upload the data to the Cart and go to the playback graph mode. 4. Select Digital PIP and analog spark. Move the cursor to the smoothest (least noise) section of the spark curve, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 4042 5. Zoom in on the recording as much as possible. Look for timing spikes that REPEAT EVERY EIGHTH FIRING OF THE DIGITAL PIP SIGNAL, Figure 2. 6. Move the cursor across all spikes to read the timing difference. NOTE: THE SPARK ADVANCE WILL SPIKE UPWARD AT LEAST 20 ON SUSPECT VEHICLES. 7. Print the graph for warranty use. ^ Downward spikes would indicate a retarded spark condition and will NOT cause detonation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 931310 > Jun > 93 > Engine - Spark Knock Diagnostic Procedure > Page 4043 ^ Graphs without spikes (Figure 3) indicate that the distributor is NOT to be replaced. 8. If spiking is found, replace the distributor with the appropriate 12127 assembly. Refer to the Dealer Master Parts Catalog for correct parts usage. a. Reuse the TFI module, cap and rotor. b. Rerun the procedure and PRINT THE NEW GRAPH to verify that the new distributor corrected the spark knock condition. c. Do not disassemble or rebuild the old distributor. d. Return the distributor with the "before and after" graphs to the Warranty Parts Return Center. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty For All Other Model Years And Emission Warranty Coverage OPERATION DESCRIPTION TIME 931310A 1985-93 5.0L (EFI/TFI) 1.5 Hrs. 1988-93 5.8L (EFI/TFI) Bronco and F-Series 931310B 1985-93 5.0L (EFI/TFI) 1.6 Hrs. 1988-93 5.8L (EFI/TFI) Econoline DEALER CODING BASIC PART NO. CONDITION CODE 12127 08 OASIS CODES: 615000, 615500, 615600 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure Technical Service Bulletin # 872110 Date: 871021 TFI Module/PIP Sensor - New Diagnostic Procedure EEC IV - TFI MODULE AND PIP SENSOR - Article No. NEW DIAGNOSTIC PROCEDURE 87-21-10 FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1983 MARK VI 1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been developed. This new procedure allows the technician to take a direct path when testing the TFI module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003). ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB. Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions. ^ Check that the TFI module is securely fastened to the distributor base. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00002. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to a shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition, refer to Intermittent Diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4048 Functional Schematic TFI-IV The TFI-IV system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage (Crank Mode) TFI-IV Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4049 Ignition Coil Secondary Voltage (Run Mode) TFI-IV Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4050 TFI-IV Part 2 Test 3 Stator - TFI Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4051 TFI-IV Part 2 Test 4 & 5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4052 Stator - TFI-IV TFI-IV Part 2 Test 5 TFI Module TFI-IV Part 2 Test 6 Ignition Coils - Secondary & Primary Resistance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4053 Ignition Coil Primary Resistance TFI-IV Part 2 Test 7 & 8 Ignition Coil Secondary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4054 Part 2 Test 8 EEC-IV - TFI-IV TFI-IV Part 2 Test 9 Ignition Coil Supply Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4055 TFI-IV Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4056 TFI-IV Part 2 Test 11 Preliminary Checkout, Equipment & Notes CHECKOUT ^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are properly routed and securely connected. ^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose, or broken conditions. ^ Be certain the battery is fully charged. ^ All accessories should be off during diagnosis. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4057 EQUIPMENT Obtain the following test equipment or an equivalent: ^ Spark Tester, Special Service Tool D81P-6666-A. See note. ^ Volt/Ohm Meter Rotunda 014-00407. ^ 12 Volt Test Light. ^ Small straight pin. ^ Remote Starter Switch. ^ TFI Ignition Tester, Rotunda 105-00003. NOTES ^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results. ^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should be performed. ^ When making measurements on a wiring harness or connector, it is good practice to wiggle the wires while measuring. ^ References to pin-in-line connector apply to shorting bar type connector used to set base timing. ^ This procedure is intended to identify faulty components or wiring while the fault is present. If the complaint is of an intermittent condition refer to Intermittent Diagnosis. Functional Schematic TFI-IV Closed Bowl Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For detailed information, refer to the vehicle wiring diagram. Ignition Coil Secondary Voltage - Crank Mode Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4058 TFI-IV Closed Bowl Distributor Part 2 Test 1 & 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4059 Ignition Coil Secondary Voltage - Run Mode TFI-IV Closed Bowl Distributor Part 2 Test 2 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4060 TFI-IV Closed Bowl Distributor Part 2 Test 3 Stator Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4061 TFI-IV Closed Bowl Distributor Part 2 Test 4, 5 & 6 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4062 Stator TFI-IV Closed Bowl Distributor Part 2 Test 5 Stator TFI-IV Closed Bowl Distributor Part 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4063 Test 6 TFI Module TFI-IV Closed Bowl Distributor Part 2 Test 7 Ignition Coil, Primary & Secondary Ignition Coil Primary Resistance TFI-IV Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4064 Closed Bowl Distributor Part 2 Test 8 Ignition Coil Secondary Resistance TFI-IV Closed Bowl Distributor Part 2 Test 9 EEC IV - Wiring Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4065 TFI-IV Closed Bowl Distributor Part 2 Test 10 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4066 TFI IV Closed Bowl Distributor Part 2 Test 11 Ignition Coil, TFI & Stator Voltage Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4067 Ignition Coil Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4068 TFI Supply Voltage TFI-IV Closed Bowl Distributor Part 2 Test 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4069 Stator Supply Voltage TFI IV Closed Bowl Distributor Part 2 Test 14 Wiring Harness Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4070 TFI IV Closed Bowl Distributor Part 2 Test 15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 86219 > Jan > 86 > Ignition System Resistance - Manual Revision Ignition Control Module: All Technical Service Bulletins Ignition System Resistance - Manual Revision Article No. 86-2-19 IGNITION SYSTEM - RESISTANCE TESTS - SHOP MANUAL REVISION EMISSION DIAGNOSIS MANUAL FORD 1982-86 ESCORT, EXP; 1983-86 LTD, THUNDERBIRD, CROWN VICTORIA, MUSTANG; 1984-86 TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1982-86 LYNX; 1983-86 MARQUIS, COUGAR, MERCURY, CONTINENTAL, MARK VII, LINCOLN; 1984-86 TOPAZ; 1986 SABLE LIGHT TRUCK 1983-86 EAND F-SERIES, BRONCO, RANGER; 1984-86 BRONCO II; 1986 AEROSTAR If your voltmeter has a high impedance, it will not draw enough current to show a voltage drop when testing TFI power circuits for resistive connections. To assure an accurate test, attach a test light between the circuit being tested and ground as shown. The light will draw current through the connection and allow measurement of the voltage drop so a resistive connection can be identified. IMPORTANT Do not use a test light while monitoring the PIP or SPOUT signal. The test light draws more current than the signal circuit can supply. The test light should be used only on power circuits. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 85173 > Aug > 85 > Engine Compartment Wiring - Connector Service Ignition Control Module: All Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4079 Component Locations - RH Side Of Engine TFI-IV Ignition Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4080 Ignition Control Module: Description and Operation Thick Film Ignition Module The TFI IV ignition module, Fig. 14, has six connector pins at the wiring harness that supplies the following signals: Run Crank (start) Tach (coil) PIP (crankshaft position to ECA) Spark output (SPOUT from ECA) Internal ground from the ECA to the distributor Ignition System The TFI IV module supplies the spark to the distributor through the ignition coil and calculates the duration. It receives its control signal from the ECA (SPOUT) Fig. 29. NOTE: Some later models use a remote module (Closed Bowl Distributors/CBD). It is located in the engine compartment (Refer to "COMPONENT LOCATIONS"). The operation is essentially the same with the exception of the CBD has a wiring harness between the ignition module and the distributor. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4081 Ignition Control Module: Service and Repair Open Bowl Distributor 1. Remove distributor cap and adapter. Position cap and wires aside. 2. Disconnect TFI wiring. 3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type hold-down bolt, if equipped. 4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2. 5. Pull right side of module down distributor mounting flange and then back up to disengage module terminals from connector in distributor base. Module may then be pulled toward flange and away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI module toward distributor flange, as pins at distributor/module connector will break otherwise. 6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease D7AZ-19A331-A, or equivalent. 7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly toward distributor bowl and securely engage 3 distributor connector pins. 8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs. 9. Install distributor on engine. 10. Install distributor cap and adapter. 11. Connect TFI wiring. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 4082 12. Check and, if necessary adjust engine timing according to decal. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4088 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4093 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure Hall Effect Sensor: Technical Service Bulletins Distributor Stator - Replacement Procedure Article No. 85-4-21 DISTRIBUTOR UNIVERSAL - ALL - STATOR REPLACEMENT FORD 1983-1985 ESCORT, EXP, TEMPO, CROWN VICTORIA, MUSTANG, THUNDERBIRD, LTD LINCOLN-MERCURY 1983-1985 LYNX, TOPAZ, CAPRI, COUGAR, MARQUIS, GRAND MARQUIS, LINCOLN, CONTINENTAL, MARK VII LIGHT TRUCK 1984-1985 BRONCO II, 1983-1985 RANGER, 1985 F-100 THRU F-250, 1984-1985 ECONOLINE The stator assembly (-12A112-) is now a serviceable component for the above vehicles. The procedures to be used when servicing the stator assembly are as follows: 1.6L EFI and 1.6L EFI T/C DISTRIBUTOR W/TFI STATOR ASSEMBLY REPLACEMENT Removal 1. Using a screwdriver, remove the distributor cap and position it and the attached wires aside so as not to interfere with work area. 2. Disconnect the TFI module from the harness. 3. Remove the distributor from the engine block. 4. Remove the rotor. 5. Remove the drive coupling spring with a small screwdriver or ice pick. Take care not to damage the drive coupling or spring. 6. a. Using an air hose, blow dirt and oil from the drive end of the distributor. b. Put a small paint dot on the drive coupling and the shaft to note orientation for re-assembly. Figure 31 - Distributor Support Tool c. Place the distributor support tool (Figure 31) in a vise and tighten or open the vise jaws wide enough to let pin drop out of the coupling but not so wide that the coupling is not supported. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4098 d. Line-up the drive pin with the slot in the base. 7. With someone holding the distributor steady on the support tool or vise, use a 5/32 inch diameter drift and hammer to drive the pin out of the shaft. 8. Remove the distributor from the fixture. Remove the drive coupling from the fixture and place aside for re-assembly. 9. Before removing the shaft from the base, check for burrs on the end of the shaft and especially around the drive pin hole. If burrs are present, polish the shaft with emery paper and wipe clean before removing the shaft from the base to prevent damage to the lip seal and bushing in the base. 10. After assuring that there are no burrs, remove shaft assembly by gently pulling up on the shaft plate. 11. Remove the two screws holding the module to the base. 12. Remove the module. Wipe grease from the base and module, keeping surfaces free of dirt. 13. Remove the octane rod retaining screw. 14. Remove the octane rod assembly. 15. Remove the two screws retaining the stator connector in the bowl of the distributor. (Retain the screws for re-assembly.) 16. Remove the stator assembly from the top of the bowl, by gently lifting up. 17. Inspect the base bushing for wear or signs of excess heat concentration, replace the complete distributor assembly if damaged. 18. Inspect the shaft oil seal for tears or cuts; replace the complete distributor assembly if oil seal is damaged. 19. Carefully check the spring retainer that holds the shaft oil seal against the shaft - it must be present and have no kinks or breaks. Replace spring if necessary. 20. Inspect the base "O" ring for cuts or damage and replace the "O" ring if necessary. 21. Inspect base casting for cracks and wear. Replace complete distributor assembly if damage is found. Re-assembly and Installation 1. Place the stator over the bushing and press down to seat. 2. Place the stator connector in position - tab should fit in the notch on the base and the fastening eyelets should be aligned with their screw holes. 3. Position the wires away from moving parts. 4. Reinstall the two stator screws and torque to specification (25-35 in.lbs.). 5. With the seal on the octane rod, insert in holes. Reinstall the octane rod through the base octane rod hole. 6. Place the end of the octane rod onto the same post as the original stator only (one post should easily fit in the octane rod hole). 7. Reinstall the octane rod screw and torque to specification (25-35 in.lbs.). 8. Wipe the back of the module and the distributor module mounting face free of all dirt. 9. Apply grease (No. WA10) to back of the module and spread evenly (thin, even coverage). 10. Turn the distributor base upside down so that the stator connector is in full view. 11. Insert the module, being sure that the three module pins are inserted into the stator connector. 12. Fully seat the module into the connector and against the base. 13. Reinstall the module screws and torque to specification (25-35 in.lbs.). 14. Apply a light coat of M2C162A oil to the distributor shaft below the armature. NOTE: Do not over-lubricate. 15. Insert the shaft assembly through the base bushing. 16. Place the drive coupling over the shaft and line up the paint dots that were made during disassembly. Start the pin into the drive coupling and shaft. 17. With someone holding the distributor steady on the support tool or vise, drive the pin into the shaft until the end of the pin is flush with the step in the drive coupling. 18. Check for free movement of the drive coupling on the pin and verify that the pin does not extend beyond the step in the coupling in either direction. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4099 19. Remove the distributor from the fixture and check for free rotation. 20. Install the drive coupling spring in the groove on the drive coupling. 21. Install the distributor assembly in the engine. 22. Install the distributor cap and rotor. 23. Install the TFI module connector. UNIVERSAL DISTRIBUTOR W/EEC (OTHER THAN 1.6L) STATOR ASSEMBLY REPLACEMENT NOTE: Do not attempt to replace the stator without an arbor press. Removal 1. Using a screwdriver, remove the distributor cap, position the cap and wires aside so as not to interfere with the work area. - Remove TFI module connector. 2. Remove distributor from block per the distributor removal procedure. 3. Remove rotor. 4. Remove the two screws holding the TFI module to the base. 5. Remove the module, wipe the grease from the base and module, keeping the surfaces free of dirt. 6. If the distributor uses the push-on rotor, remove the two screws holding the armature and remove the armature. NOTE: Hold the gear to loosen the armature screws, do not hold the armature. 7. To ease re-assembly, mark with a felt tip pen, the armature, gear and collar if present (Refer to the following chart.) to note orientation. 8. Remove and discard pins in gear and collar if present (Refer to chart.). Figure 32 - Bearing Removal Tool 9. Invert the distributor and place in the Axle Bearing/Seal Plate (Tool D84L-950-A) and press off the gear using the Bearing Removal Tool (T75L-1165-B) as shown in Figure 32. 10. Deburr and polish shaft with emery paper and wipe such that the shaft slides out freely from distributor base. 11. Remove shaft assembly. 12. Remove thrust washer from distributor shaft and retain. 13. Remove octane rod retaining screw and retain. 14. Remove octane rod assembly and retain. GEAR GEAR THRUST ROLL PIN COLLAR ENGINE GEAR PIN WASHER EXTRUSION COLLAR PIN 2.3L HSC 67555-S FLUSH Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4100 2.3L OHC 67555-S FLUSH 2.8L 67575-S FLUSH 3.8L 67555-S FLUSH X 67555-S 4.9L 67775-S2 X EXTRUDE EVENLY, BOTH SIDES 5.0L 67555-S FLUSH X 67555-S 6.1L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 7.0L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 7.5L 67775-S2 EXTRUDE EVENLY, X 67555-S BOTH SIDES 15. Remove two stator assembly screws and retain. 16. Remove stator assembly from top of bowl. 17. Inspect base bushing for wear or signs of excess heat concentration, replace complete distributor assembly if damaged. 18. Inspect base "O" ring for cuts or damage and replace "O" ring if necessary. 19. Inspect base for cracks and wear. Replace complete distributor assembly if damage is found. Re-assembly and Installation 1. Place the stator assembly over the bushing and press down to seat. 2. Place the stator connector in position - tab should fit in notch on base and fastening eyelets aligned with screw holes. 3. Position wires away from moving parts. 4. Install the two stator screws and torque to specification (25-35 in.lbs.). 5. Reinstall the octane rod, inserting rod through the base hole. 6. Place end of octane rod onto the same post as the original stator. Only one post should easily fit in rod hole. 7. Firmly seat octane rod seal into housing. 8. Reinstall the octane rod screw and torque to specification (25-35 in./lbs.). 9. If required, reinstall the thrust washer on top of the bushing. 10. Apply a light coat of ESF-M2C70-A to the distributor shaft below the armature. 11. Insert the shaft through the base bushing. 12. Place the collar, if required, over the shaft and line up mark on armature and collar to aid alignment with original drill hole. Use a drift punch to assure proper alignment. NOTE: Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, the collar may be 180 degrees out of alignment on the shaft. Rotate the collar on the shaft one half rotation and recheck. 13. Insert new roll pin (Part No. 67555-S) through collar and shaft. Pin should be flush with both sides of collar when seated. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4101 Figure 33 - Push On Rotor Figure 34 - Screw Down Rotor 14. If the distributor uses a push-on rotor, place a 1/2 inch deep well socket over the shaft (Figure 33), invert and place on arbor plate. 14a. If the distributor uses a screw-down rotor, invert and place on arbor plate (Figure 34). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4102 Figure 35 - Press Gear 15. Place the distributor gear on the shaft and line up the mark on the armature and gear. NOTE: The hole in the shaft and gear must be lined up as accurately as possible to assure ease of roll pin insertion. 16. Place a 5/8 inch deep well socket over the shaft and gear (Figure 35) and press gear to align with original drill hole. NOTE: If the gear holes do not align, the gear must be removed and repressed on. A drift punch will not align the holes. As in the collar, the holes should align. 17. Insert new roll pin (Refer to chart following Step 7 in the Removal Procedure) through gear and shaft. Pin should have proper extrusion, as referenced in same chart. 18. If the armature was removed, replace and torque screws to 25-35 in.lbs. 19. Check distributor for free movement over full rotation of shaft. NOTE: If the armature hits the stator; replace the entire distributor. 20. Wipe back of module and distributor module mounting face free of all dirt. 21. Apply grease (No. WA10) to the back of the module and spread evenly (thin, even coverage). 22. Turn the distributor base upside down such that the stator connector is in full view. 23. Insert the module and watch that the three module pins are inserted into the stator connector. Fully seat the module into the connector and against base. 24. Reinstall two module screws and torque to specification (25-35 in.lbs.). 25. Reinstall the distributor into block per distributor replacement procedure. 26. Connect TFI module to wiring harness. 27. Replace rotor and torque screws to specification. 28. Replace cap and torque screws to specification. 29. Retime engine. PART NUMBER PART NAME CLASS 67555-S Pin BS 67775-S2 Pin RS E3ZZ-12A112-C Stator A OTHER APPLICABLE ARTICLES: None Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4103 WARRANTY STATUS: "INFORMATION ONLY" OPERATION: STATOR REPLACE 12112D1 TIME: 1.6L Engine 0.6 HR. All Others 0.5 HR. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4104 Hall Effect Sensor: Technical Service Bulletins Engine - No Start/Idles Rough/Knock When Cold Article No. 85-7-11 (Supercedes Article No. 85-4-20) 04/04/85 NO START - ALL EEC IV IDLE ROUGH - ALL EEC IV - COLD SPARK KNOCK - ALL EEC IV COLD FORD: 1984-85 ESCORT, EXP, TEMPO, MUSTANG, THUNDERBIRD, LTD, CROWN VICTORIA LINCOLN-MERCURY: 1984-85 LYNX, LN7 TOPAZ, CAPRI, COUGAR, MARQUIS, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN LIGHT TRUCK: 1984-85 BRONCO II; 1983, 84, 85 RANGER; 1984-85 F100 THRU F-250; 1984-85 ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4105 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4106 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4107 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4108 This article is being republished to revise Test 5. The above concerns can be caused by the distributor Hall Effect sensor. When the above concerns occur only at cold temperatures and the engine starts and runs satisfactorily when warm, use the first diagnostic procedure. If the concern is no start, use the second procedure. If a T.F.I. is removed from the distributor and the stator connector is soft or mushy, replace the stator. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" TFI Module Side of the SPOUT Connector Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Distributor Stator - Replacement Procedure > Page 4109 Terminal Voltage Measurement Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 4110 Hall Effect Sensor: Description and Operation Profile Ignition Pickup The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA. PIP Sensor COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator, Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the output is high. When the signal is high the output is low. This output then goes to the Schmitt trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 4111 PIP Signal Operation OPERATION The output signal to the Darlington amplifier is high when the window (on the armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington amplifier (switch on). Hall Effect Sensor In other words when one of the windows or openings is in the gap between the Hall device and the permanent magnet, the field stays strong and the voltage is high since the magnetic path is complete from the magnet, through the Hall device, and back to the magnet. In this case the switch is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the TFI module if the SPOUT signal from the ECA is lost. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Page 4112 Signature PIP SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature profile ignition pickup signal. The regular type armature used for the PIP signal has the same size tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors. This system is used on cars and trucks where the ECA needs to know when to pulse certain injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the No. 1 cylinder needs to be supplied with fuel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 4121 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 4127 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 4128 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUGS Gap ...................................................................................................................................................... ............................................................ 0.044 in Torque ...................................................................... ................................................................................................................. 9-20 Nm (7-15 ft-lbs) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4135 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications - Install each spark plug and tighten to 9-20 Nm (7-15 ft-lbs). Cylinder Numbering And Distributor Location Location On Distributor - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Powertrain Management > Ignition System > Vacuum Restrictor > Component Information > Description and Operation Vacuum Restrictor: Description and Operation Fig. 38 Vacuum restrictor The orifice type flow restrictor, Fig. 38, 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > C5 Transmission > Page 4147 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > C5 Transmission > Page 4148 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4162 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 (V8-302 5.0L (1985)) 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 4163 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4168 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4178 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 (V8-302 5.0L (1985)) 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 4179 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4184 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Refill Capacity Fluid - A/T: Specifications TYPE MA CAPACITY, Initial Refill*: C-6 5.0 qt (US) With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed Others 3.0 qt (US) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Refill Capacity > Page 4187 Fluid - A/T: Specifications Fluid Capacity Note: C6 units, 11.8 qts.; automatic overdrive units, 12 qts. Approximate. Make final check with dipstick. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4192 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4193 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4202 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 (V8-302 5.0L (1985)) 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 4203 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4209 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 (V8-302 5.0L (1985)) 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 4210 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4215 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 861914 > Sep > 86 > A/T - AOD Harsh/Delayed Shifting Throttle Valve Assembly: Customer Interest A/T - AOD Harsh/Delayed Shifting Article No. 86-19-14 09/24/86 TRANSMISSION - AUTOMATIC - AOD - SHIFTING HARSH/DELAYED - ALL WITH 5.0L EFI LIGHT TRUCK: 1985-87 E150-250, F150-250, BRONCO Unusually firm or harsh and/or delayed shifts may be experienced on some of the subject vehicles. Light trucks, vans and Broncos with the 5.0L EFI engine and the AOD transmission may have TV pressure set near or above the TV pressure specification of 35 psi and experience harsh and/or delayed shifts. It has been determined that on a customer concern basis, the TV pressure may be set lower to eliminate the concerns without affecting the transmission durability. Following the procedure (TV Control Pressure Check and Adjustment Procedure with Engine ON) detailed in Section 17-20 of the Light Truck Shop Manual, reset the TV pressure to 29 psi with the shift selector in Neutral. This will result in a TV pressure of approximately 31 psi when the shift selector is moved to a forward gear ((D) or D). This is 4 psi lower than the 35 psi previously specified as being optimum in a forward gear. IMPORTANT This procedure applies ONLY to Light Trucks, Vans, and Broncos equipped with 5.0L EFI engines. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 7042AT TIME: 0.4 Hr. - F Series, Bronco 0.5 Hr. - Econoline DLR. CODING: Basic Part No. 7000 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 861914 > Sep > 86 > A/T AOD Harsh/Delayed Shifting Throttle Valve Assembly: All Technical Service Bulletins A/T - AOD Harsh/Delayed Shifting Article No. 86-19-14 09/24/86 TRANSMISSION - AUTOMATIC - AOD - SHIFTING HARSH/DELAYED - ALL WITH 5.0L EFI LIGHT TRUCK: 1985-87 E150-250, F150-250, BRONCO Unusually firm or harsh and/or delayed shifts may be experienced on some of the subject vehicles. Light trucks, vans and Broncos with the 5.0L EFI engine and the AOD transmission may have TV pressure set near or above the TV pressure specification of 35 psi and experience harsh and/or delayed shifts. It has been determined that on a customer concern basis, the TV pressure may be set lower to eliminate the concerns without affecting the transmission durability. Following the procedure (TV Control Pressure Check and Adjustment Procedure with Engine ON) detailed in Section 17-20 of the Light Truck Shop Manual, reset the TV pressure to 29 psi with the shift selector in Neutral. This will result in a TV pressure of approximately 31 psi when the shift selector is moved to a forward gear ((D) or D). This is 4 psi lower than the 35 psi previously specified as being optimum in a forward gear. IMPORTANT This procedure applies ONLY to Light Trucks, Vans, and Broncos equipped with 5.0L EFI engines. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 7042AT TIME: 0.4 Hr. - F Series, Bronco 0.5 Hr. - Econoline DLR. CODING: Basic Part No. 7000 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Assembly: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: All Technical Service Bulletins Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Assembly: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 4234 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Valve Assembly: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 4240 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Cable/Linkage: > 861914 > Sep > 86 > A/T - AOD Harsh/Delayed Shifting Throttle Valve Cable/Linkage: Customer Interest A/T - AOD Harsh/Delayed Shifting Article No. 86-19-14 09/24/86 TRANSMISSION - AUTOMATIC - AOD - SHIFTING HARSH/DELAYED - ALL WITH 5.0L EFI LIGHT TRUCK: 1985-87 E150-250, F150-250, BRONCO Unusually firm or harsh and/or delayed shifts may be experienced on some of the subject vehicles. Light trucks, vans and Broncos with the 5.0L EFI engine and the AOD transmission may have TV pressure set near or above the TV pressure specification of 35 psi and experience harsh and/or delayed shifts. It has been determined that on a customer concern basis, the TV pressure may be set lower to eliminate the concerns without affecting the transmission durability. Following the procedure (TV Control Pressure Check and Adjustment Procedure with Engine ON) detailed in Section 17-20 of the Light Truck Shop Manual, reset the TV pressure to 29 psi with the shift selector in Neutral. This will result in a TV pressure of approximately 31 psi when the shift selector is moved to a forward gear ((D) or D). This is 4 psi lower than the 35 psi previously specified as being optimum in a forward gear. IMPORTANT This procedure applies ONLY to Light Trucks, Vans, and Broncos equipped with 5.0L EFI engines. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 7042AT TIME: 0.4 Hr. - F Series, Bronco 0.5 Hr. - Econoline DLR. CODING: Basic Part No. 7000 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Cable/Linkage: > 861914 > Sep > 86 > A/T - AOD Harsh/Delayed Shifting Throttle Valve Cable/Linkage: All Technical Service Bulletins A/T - AOD Harsh/Delayed Shifting Article No. 86-19-14 09/24/86 TRANSMISSION - AUTOMATIC - AOD - SHIFTING HARSH/DELAYED - ALL WITH 5.0L EFI LIGHT TRUCK: 1985-87 E150-250, F150-250, BRONCO Unusually firm or harsh and/or delayed shifts may be experienced on some of the subject vehicles. Light trucks, vans and Broncos with the 5.0L EFI engine and the AOD transmission may have TV pressure set near or above the TV pressure specification of 35 psi and experience harsh and/or delayed shifts. It has been determined that on a customer concern basis, the TV pressure may be set lower to eliminate the concerns without affecting the transmission durability. Following the procedure (TV Control Pressure Check and Adjustment Procedure with Engine ON) detailed in Section 17-20 of the Light Truck Shop Manual, reset the TV pressure to 29 psi with the shift selector in Neutral. This will result in a TV pressure of approximately 31 psi when the shift selector is moved to a forward gear ((D) or D). This is 4 psi lower than the 35 psi previously specified as being optimum in a forward gear. IMPORTANT This procedure applies ONLY to Light Trucks, Vans, and Broncos equipped with 5.0L EFI engines. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: 7042AT TIME: 0.4 Hr. - F Series, Bronco 0.5 Hr. - Econoline DLR. CODING: Basic Part No. 7000 - Code: 09 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 92186 > Aug > 92 > Engine - Metal to Metal Noise Torque Converter: Customer Interest Engine - Metal to Metal Noise Article No. 92-18-6 08/26/92 ^ ENGINE - 5.0L - THRUST BEARING OR CRANKSHAFT PREMATURE WEAR - VEHICLES WITH AOD TRANSMISSION ^ NOISE - "METAL-TO-METAL" SOUND - 5.0L WITH AOD TRANSMISSION ^ TRANSMISSION - AOD - INTERFERENCE BETWEEN THE TORQUE CONVERTER AND THE FLYWHEEL BOLTS FORD: 1982-88 THUNDERBIRD 1982-90 MUSTANG 1986 LTD 1987-90 CROWN VICTORIA LINCOLN-MERCURY: 1982-87 CAPRI, CONTINENTAL 1982-88 COUGAR 1982-90 TOWN CAR 1984-90 MARK VII 1987-90 GRAND MARQUIS LIGHT TRUCK: 1982-90 BRONCO, E-150, E-250, F-150, F-250 This TSB article is being republished in its entirety to include the 1982-1987 Continental and the 1982-1990 Town Car. ISSUE: An unusual "metal-to-metal" noise from the engine may be caused by the flexing of the torque converter. The flexing condition causes an interference between the torque converter and flywheel bolts. The interference can cause the thrust bearing and the crankshaft to wear prematurely and eventually fail. ACTION: Install six (6) new flywheel bolts with reduced head height to provide additional clearance. Refer to the appropriate Shop Manual, 5.0L Engine Section, for service details. NOTE: WHEN A CRANKSHAFT IS REPLACED DUE TO THRUST BEARING FAILURE, INSTALL A NEW CRANKSHAFT THAT HAS A REVISED PILOT HOLE. THIS WILL PROVIDE ADDITIONAL CLEARANCE FOR THE TOROUE CONVERTER. USE NEW FLYWHEEL BOLTS. PART NUMBER Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 92186 > Aug > 92 > Engine - Metal to Metal Noise > Page 4262 Operation Description Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 4268 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 4269 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure Torque Converter: All Technical Service Bulletins A/T Torque Converter - Leak Test Procedure Article No. 96-24-9 11/18/96 TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1984-90 BRONCO II 1984-96 BRONCO 1984-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: A new torque converter leak test tool has been released. The current leak test tool has been discontinued by the manufacturer. The new tool will be available to all dealers in 1997. ACTION: When using the new leak test tool, a new procedure must be followed. Refer to the following Service Procedure and/or the 1997 Service/Workshop Manuals when using the new leak test tool. NEW TOOL NUMBER Description Tool Number Torque converter Leak Test Tool and Gasket 014-R1075 SERVICE PROCEDURE 1. Clean the outside surface of the torque converter. CAUTION: BE CAREFUL NOT TO DAMAGE THE CONVERTER HUB FINISH WHEN INSTALLING THE TOOL. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4274 2. Install the Torque Converter Leak Test Tool and Gasket (O14-R1075) into the converter hub. Figure 1. WARNING: ALWAYS USE PROPER SAFETY PROCEDURES WHILE USING PRESS. CAUTION: DO NOT DAMAGE THE CONVERTER BY APPLYING EXCESSIVE FORCE FROM THE PRESS. USE ONLY ENOUGH FORCE TO SEAL TOOL INTO THE CONVERTER. 3. Place the torque converter with the tool installed into press and apply enough force to seal tool into the converter. Figure 2. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4275 4. Using clean, dry shop air only, apply air pressure of 552 kPa (80 psi) maximum to the valve on the tool. Refer to Figure 3. 5. With air pressure applied to the valve, inspect for any air leaks at the studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If any leaks are present, replace the converter. 6. Disconnect the air line and release the air pressure from the tool by pulling on the release ring and then slowly releasing the press. Refer to Figure 4. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4276 7. Turn the torque converter and tool upside down and reinstall into the press. Repeat Steps 2-6 to check for leaks on the opposite side. Refer to Figure 5. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 504000, 510000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 92186 > Aug > 92 > Engine - Metal to Metal Noise Torque Converter: All Technical Service Bulletins Engine - Metal to Metal Noise Article No. 92-18-6 08/26/92 ^ ENGINE - 5.0L - THRUST BEARING OR CRANKSHAFT PREMATURE WEAR - VEHICLES WITH AOD TRANSMISSION ^ NOISE - "METAL-TO-METAL" SOUND - 5.0L WITH AOD TRANSMISSION ^ TRANSMISSION - AOD - INTERFERENCE BETWEEN THE TORQUE CONVERTER AND THE FLYWHEEL BOLTS FORD: 1982-88 THUNDERBIRD 1982-90 MUSTANG 1986 LTD 1987-90 CROWN VICTORIA LINCOLN-MERCURY: 1982-87 CAPRI, CONTINENTAL 1982-88 COUGAR 1982-90 TOWN CAR 1984-90 MARK VII 1987-90 GRAND MARQUIS LIGHT TRUCK: 1982-90 BRONCO, E-150, E-250, F-150, F-250 This TSB article is being republished in its entirety to include the 1982-1987 Continental and the 1982-1990 Town Car. ISSUE: An unusual "metal-to-metal" noise from the engine may be caused by the flexing of the torque converter. The flexing condition causes an interference between the torque converter and flywheel bolts. The interference can cause the thrust bearing and the crankshaft to wear prematurely and eventually fail. ACTION: Install six (6) new flywheel bolts with reduced head height to provide additional clearance. Refer to the appropriate Shop Manual, 5.0L Engine Section, for service details. NOTE: WHEN A CRANKSHAFT IS REPLACED DUE TO THRUST BEARING FAILURE, INSTALL A NEW CRANKSHAFT THAT HAS A REVISED PILOT HOLE. THIS WILL PROVIDE ADDITIONAL CLEARANCE FOR THE TOROUE CONVERTER. USE NEW FLYWHEEL BOLTS. PART NUMBER Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 92186 > Aug > 92 > Engine - Metal to Metal Noise > Page 4281 Operation Description Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 85119 > Jun > 85 > A/T - AOD Service Tip/Manual Update Torque Converter: All Technical Service Bulletins A/T - AOD Service Tip/Manual Update Article No. 85-11-9 TRANSMISSION - AUTOMATIC - AOD - SERVICE TIPS/SHOP MANUAL UPDATE FOR LOW MILEAGE OVERHAULS FORD 1984-85 FORD, THUNDERBIRD, MUSTANG, LTD LINCOLN-MERCURY 1984-85 MERCURY, COUGAR, CAPRI, MARQUIS, LINCOLN, MARK VII, CONTINENTAL LIGHT TRUCK 1984-85 E & F SERIES, BRONCO Figure 9REVERSE SUN GEAR & DRIVE SHELL Contamination blocking the converter drainback valve could prevent proper lubrication and result in overheating and malfunction of various transmission components. Any overheating will be indicated by heat stained blue surfaces on the forward sun gear, reverse sun gear and drive shell and the planetary assembly. Refer to Figure 9. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 85119 > Jun > 85 > A/T - AOD Service Tip/Manual Update > Page 4286 Figure 8 When overhauling a low mileage AOD transmission with evidence of overheating, inspect the converter drainback cross hole passage in the pump stator support for contamination, or a spring compressed solid which would indicate a stuck open check ball. (See Figure 8, Hole No. 13.) NOTE: A low mileage vehicle is considered to have approximately 5,000 miles or less on the odometer. The converter drainback valve in Hole No. 12 of the pump stator support consists of a spring and a ball with an aluminum ball plug pressed in the passage. If contamination can be seen in the exposed cross hole passage area or if the spring is compressed solid which would indicate a stuck open check ball (can be seen when the stator support is turned over-refer to Figure 8, Hole No. 13), then follow the procedure included here for removal and cleaning of the converter drainback valve. In addition, the converter will have to be replaced. Converter Drainback Check Valve Removal and Cleaning Procedure 1. To remove the drainback valve (check ball and spring) in Hole No. 12, remove the aluminum ball plug. This can be done by using a suitable punch inserted into the cross Hole No. 13. (See Figure 8.) Discard the aluminum ball plug and the spring. The check ball must be retained for reinstallation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 85119 > Jun > 85 > A/T - AOD Service Tip/Manual Update > Page 4287 Figure 10 2. Flush and clean the passage. 3. Install the check ball and a new spring. Press in flush a new aluminum ball plug as indicated in Figure 10. 4. Reassemble the pump body and stator support assembly according to the procedure in the appropriate model year Shop Manual. 5. Install a new torque converter. General Transmission Instructions (Typically done during any transmission overhaul) 1. Overhaul the transmission making sure to inspect all hardware for evidence of overheating. Replace parts as necessary. Follow the inspection procedure in Section 17-01 of the Shop Manual. 2. Before reassembly, thoroughly clean all transmission components including the check balls in the forward clutch cylinder, the reverse clutch piston, and the direct clutch piston. Follow the cleaning procedure in Section 17-01 of the Shop Manual. 3. The cooler lines, the intake cooler and the auxiliary cooler (if equipped) should be thoroughly FLUSHED out before reinstalling the transmission. PART NUMBER PART NAME CLASS E5AZ-7A205-A Spring & Ball - Kit C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 4293 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 962612 > Dec > 96 > Torque Converter - Cleaning and Replacement Guidelines > Page 4294 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure Torque Converter: All Technical Service Bulletins A/T Torque Converter - Leak Test Procedure Article No. 96-24-9 11/18/96 TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1984-90 BRONCO II 1984-96 BRONCO 1984-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: A new torque converter leak test tool has been released. The current leak test tool has been discontinued by the manufacturer. The new tool will be available to all dealers in 1997. ACTION: When using the new leak test tool, a new procedure must be followed. Refer to the following Service Procedure and/or the 1997 Service/Workshop Manuals when using the new leak test tool. NEW TOOL NUMBER Description Tool Number Torque converter Leak Test Tool and Gasket 014-R1075 SERVICE PROCEDURE 1. Clean the outside surface of the torque converter. CAUTION: BE CAREFUL NOT TO DAMAGE THE CONVERTER HUB FINISH WHEN INSTALLING THE TOOL. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4299 2. Install the Torque Converter Leak Test Tool and Gasket (O14-R1075) into the converter hub. Figure 1. WARNING: ALWAYS USE PROPER SAFETY PROCEDURES WHILE USING PRESS. CAUTION: DO NOT DAMAGE THE CONVERTER BY APPLYING EXCESSIVE FORCE FROM THE PRESS. USE ONLY ENOUGH FORCE TO SEAL TOOL INTO THE CONVERTER. 3. Place the torque converter with the tool installed into press and apply enough force to seal tool into the converter. Figure 2. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4300 4. Using clean, dry shop air only, apply air pressure of 552 kPa (80 psi) maximum to the valve on the tool. Refer to Figure 3. 5. With air pressure applied to the valve, inspect for any air leaks at the studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If any leaks are present, replace the converter. 6. Disconnect the air line and release the air pressure from the tool by pulling on the release ring and then slowly releasing the press. Refer to Figure 4. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 96249 > Nov > 96 > A/T Torque Converter - Leak Test Procedure > Page 4301 7. Turn the torque converter and tool upside down and reinstall into the press. Repeat Steps 2-6 to check for leaks on the opposite side. Refer to Figure 5. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 504000, 510000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 85119 > Jun > 85 > A/T - AOD Service Tip/Manual Update Torque Converter: All Technical Service Bulletins A/T - AOD Service Tip/Manual Update Article No. 85-11-9 TRANSMISSION - AUTOMATIC - AOD - SERVICE TIPS/SHOP MANUAL UPDATE FOR LOW MILEAGE OVERHAULS FORD 1984-85 FORD, THUNDERBIRD, MUSTANG, LTD LINCOLN-MERCURY 1984-85 MERCURY, COUGAR, CAPRI, MARQUIS, LINCOLN, MARK VII, CONTINENTAL LIGHT TRUCK 1984-85 E & F SERIES, BRONCO Figure 9REVERSE SUN GEAR & DRIVE SHELL Contamination blocking the converter drainback valve could prevent proper lubrication and result in overheating and malfunction of various transmission components. Any overheating will be indicated by heat stained blue surfaces on the forward sun gear, reverse sun gear and drive shell and the planetary assembly. Refer to Figure 9. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 85119 > Jun > 85 > A/T - AOD Service Tip/Manual Update > Page 4306 Figure 8 When overhauling a low mileage AOD transmission with evidence of overheating, inspect the converter drainback cross hole passage in the pump stator support for contamination, or a spring compressed solid which would indicate a stuck open check ball. (See Figure 8, Hole No. 13.) NOTE: A low mileage vehicle is considered to have approximately 5,000 miles or less on the odometer. The converter drainback valve in Hole No. 12 of the pump stator support consists of a spring and a ball with an aluminum ball plug pressed in the passage. If contamination can be seen in the exposed cross hole passage area or if the spring is compressed solid which would indicate a stuck open check ball (can be seen when the stator support is turned over-refer to Figure 8, Hole No. 13), then follow the procedure included here for removal and cleaning of the converter drainback valve. In addition, the converter will have to be replaced. Converter Drainback Check Valve Removal and Cleaning Procedure 1. To remove the drainback valve (check ball and spring) in Hole No. 12, remove the aluminum ball plug. This can be done by using a suitable punch inserted into the cross Hole No. 13. (See Figure 8.) Discard the aluminum ball plug and the spring. The check ball must be retained for reinstallation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 85119 > Jun > 85 > A/T - AOD Service Tip/Manual Update > Page 4307 Figure 10 2. Flush and clean the passage. 3. Install the check ball and a new spring. Press in flush a new aluminum ball plug as indicated in Figure 10. 4. Reassemble the pump body and stator support assembly according to the procedure in the appropriate model year Shop Manual. 5. Install a new torque converter. General Transmission Instructions (Typically done during any transmission overhaul) 1. Overhaul the transmission making sure to inspect all hardware for evidence of overheating. Replace parts as necessary. Follow the inspection procedure in Section 17-01 of the Shop Manual. 2. Before reassembly, thoroughly clean all transmission components including the check balls in the forward clutch cylinder, the reverse clutch piston, and the direct clutch piston. Follow the cleaning procedure in Section 17-01 of the Shop Manual. 3. The cooler lines, the intake cooler and the auxiliary cooler (if equipped) should be thoroughly FLUSHED out before reinstalling the transmission. PART NUMBER PART NAME CLASS E5AZ-7A205-A Spring & Ball - Kit C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4312 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4313 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 851012 > May > 85 > A/T - AOD No Forward Drive Condition Valve Body: Customer Interest A/T - AOD No Forward Drive Condition Article No. 85-10-12 TRANSMISSION - AUTOMATIC - AOD - NO FORWARD DRIVE AFTER COAST DOWN FROM FOURTH GEAR FORD 1983-1985 FORD, THUNDERBIRD, LTD, MUSTANG LINCOLN-MERCURY 1983-85 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, MARK, CONTINENTAL LIGHT TRUCK 1983-85 E & F SERIES Some AOD-equipped vehicles with transmissions built between March, 1983 and April 19, 1985, may exhibit a no forward drive condition after coast down from fourth gear. This condition may occur if a small particle of contamination causes the 3-4 shift valve to stick in the forward clutch exhaust position. Figure 11 - 3-4 SHIFT VALVE DESIGN To service this condition, install a new 3-4 shift valve that has a design with flats on the valve. This will allow contamination to pass and be trapped in the main control filter assembly. The new valve was incorporated in production April 19, 1985. Refer to Figure 11 for visual differences between 3-4 shift valve design levels. PROCEDURE: 1. Verify that the transmission was built between March 1, 1983 and April 9, 1985. 2. Remove the main control assembly from the vehicle according to the Main Control Removal Procedure in Section 17-20 of the appropriate model year Car or Truck Shop Manual. 3. Partially disassemble the valve body to expose the valve body face by following Steps 1 and 2 of the Valve Body Disassembly Procedure in Section 17- 20 of the Shop Manual. This involves removing the separator plate, valve body gasket and all check balls. 4. Attempt to verify the concern by visually checking the 3-4 shift valve to see if a small particle of contamination is blocking the valve. 5. Remove the 3-4 shift valve bore sleeve from bore No. 5 as illustrated in the Shop Manual. The valve should fall out freely. Remove all springs and the 3-4 TV modulator valve. 6. Thoroughly clean the bore passage with solvent. 7. Pour solvent cleaner over the valve body face, spill solvent from passages, and blow dry with clean compressed air. 8. Replace the 3-4 shift valve with the flatted design (Part No. E5AZ-7F259-A). Reassemble the 3-4 TV modulator valve and spring, the new 3-4 shift valve and spring, the throttle plug sleeve, and the retaining clip in bore No. 5 as illustrated in the Shop Manual. 9. Reassemble the valve body by reversing Steps 1 and 2 of the Valve Body Disassembly Procedure. Be sure to use a new valve body gasket. 10. Reinstall the valve body by reversing Steps 1 and 2 of the Valve Body Disassembly Procedure. Be sure to use a new valve body gasket. 11. Reinstall the valve body on the transmission according to the Valve Body Installation Procedure in Section 17-20 of the Shop Manual. PART NUMBER PART NAME CLASS E5AZ-7F259-A 3-4 Shift Valve C OTHER APPLICABLE ARTICLES: None Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 851012 > May > 85 > A/T - AOD No Forward Drive Condition > Page 4322 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: Refer to the Labor Standards Manual for applicable operation and time. 77396A2 TIME: 1.3 Hrs. DLR CODING: Basic Part No. 7A100 - Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89237 > Nov > 89 > A/T - AOD Separator Plate Gasket Changes Valve Body: All 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 861317 > Jul > 86 > A/T - AOD Main Control Valve Body Gasket Valve Body: All 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 861317 > Jul > 86 > A/T - AOD Main Control Valve Body Gasket > Page 4332 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 86110 > Jan > 86 > A/T - AOD Revised Valve Body Assembly Valve Body: All Technical Service Bulletins A/T - AOD Revised Valve Body Assembly Article No. 86-1-10 TRANSMISSION - AUTOMATIC - AOD REVISED VALVE BODY ASSEMBLY LIGHT TRUCK 1985-86 E, F SERIES, BRONCO The 1985-1/2 and early 1986 5.0L EFI truck, Bronco, and Econoline applications with the AOD transmission were built with main control valve bodies that have been superseded with main controls that are not listed in the Master Parts Catalog yet. For field concerns that require replacing the main control, follow the chart below to ensure the latest level main control is used. Axle Original Revised Ratio Model Part Number Part Number Class 3.50/ E/F/B DTY-E5AZ-7A100-C E6TZ-7A100-D C 3.55/ 3.73 4.10/ F/B DTR-E5TZ-7A100-G E6TZ-7A100-E C 4.11 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" DLR. CODING: Basic Part No. 7A100 - Code: 38 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 85147 > Jul > 85 > A/T - AOD Orifice Control Valve Plug Retainer Valve Body: All 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 851012 > May > 85 > A/T - AOD No Forward Drive Condition Valve Body: All Technical Service Bulletins A/T - AOD No Forward Drive Condition Article No. 85-10-12 TRANSMISSION - AUTOMATIC - AOD - NO FORWARD DRIVE AFTER COAST DOWN FROM FOURTH GEAR FORD 1983-1985 FORD, THUNDERBIRD, LTD, MUSTANG LINCOLN-MERCURY 1983-85 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, MARK, CONTINENTAL LIGHT TRUCK 1983-85 E & F SERIES Some AOD-equipped vehicles with transmissions built between March, 1983 and April 19, 1985, may exhibit a no forward drive condition after coast down from fourth gear. This condition may occur if a small particle of contamination causes the 3-4 shift valve to stick in the forward clutch exhaust position. Figure 11 - 3-4 SHIFT VALVE DESIGN To service this condition, install a new 3-4 shift valve that has a design with flats on the valve. This will allow contamination to pass and be trapped in the main control filter assembly. The new valve was incorporated in production April 19, 1985. Refer to Figure 11 for visual differences between 3-4 shift valve design levels. PROCEDURE: 1. Verify that the transmission was built between March 1, 1983 and April 9, 1985. 2. Remove the main control assembly from the vehicle according to the Main Control Removal Procedure in Section 17-20 of the appropriate model year Car or Truck Shop Manual. 3. Partially disassemble the valve body to expose the valve body face by following Steps 1 and 2 of the Valve Body Disassembly Procedure in Section 17- 20 of the Shop Manual. This involves removing the separator plate, valve body gasket and all check balls. 4. Attempt to verify the concern by visually checking the 3-4 shift valve to see if a small particle of contamination is blocking the valve. 5. Remove the 3-4 shift valve bore sleeve from bore No. 5 as illustrated in the Shop Manual. The valve should fall out freely. Remove all springs and the 3-4 TV modulator valve. 6. Thoroughly clean the bore passage with solvent. 7. Pour solvent cleaner over the valve body face, spill solvent from passages, and blow dry with clean compressed air. 8. Replace the 3-4 shift valve with the flatted design (Part No. E5AZ-7F259-A). Reassemble the 3-4 TV modulator valve and spring, the new 3-4 shift valve and spring, the throttle plug sleeve, and the retaining clip in bore No. 5 as illustrated in the Shop Manual. 9. Reassemble the valve body by reversing Steps 1 and 2 of the Valve Body Disassembly Procedure. Be sure to use a new valve body gasket. 10. Reinstall the valve body by reversing Steps 1 and 2 of the Valve Body Disassembly Procedure. Be sure to use a new valve body gasket. 11. Reinstall the valve body on the transmission according to the Valve Body Installation Procedure in Section 17-20 of the Shop Manual. PART NUMBER PART NAME CLASS E5AZ-7F259-A 3-4 Shift Valve C OTHER APPLICABLE ARTICLES: None Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 851012 > May > 85 > A/T - AOD No Forward Drive Condition > Page 4345 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: Refer to the Labor Standards Manual for applicable operation and time. 77396A2 TIME: 1.3 Hrs. DLR CODING: Basic Part No. 7A100 - Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 85418 > Feb > 85 > A/T - AOD Main Control Revisions Valve Body: All Technical Service Bulletins A/T - AOD Main Control Revisions Article No. 85-4-18 TRANSMISSION AOD -1985 MAIN CONTROL REVISIONS FORD 1985 FORD, THUNDERBIRD, LTD, MUSTANG LINCOLN-MERCURY 1985 LINCOLN, MERCURY, CONTINENTAL, MARQUIS, COUGAR, CAPRI, MARK VII LIGHT TRUCK E & F SERIES AND BRONCO Two minor revisions to the AOD main control valve body are to be incorporated during the 1985 model year. These changes are: 1. A new plug retainer plate will replace the hairpin clip at the orifice control valve bore. (Refer to the main control valve body illustration in the 1985 Shop Manual for the location of the valve bore). The production incorporation date is approximately March, 1985. 2. As a calibration change, a new retaining plug with a pocket and a longer spring will be incorporated in the 2-3 backout bore. (Refer to the main control valve body illustration in the 1985 shop manual for the location of the valve bore). The production incorporation date was January, 1985. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 4355 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 4361 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Description and Operation Clutch Disc: Description and Operation DESCRIPTION AND OPERATION The purpose of the clutch is to connect and disconnect a manually operated transmission and the remainder of the power-transmission system from the engine. This permits starting and stopping the vehicle, shifting and changing speeds that correspond to the engine speed through gear reductions for both forward and reverse directions. The clutch consists of a driven plate (clutch disc) splined for the input shaft of the transmission and the clutch housing (pressure plate). This forms a continuous system by which rotation of the engine is connected to the transmission by solid member when engaged (clutch assembly). For power at the output shaft of the transmission or rear wheel rotation (forward or reverse), the driven plate is a metal disc, faced on both sides with woven friction materials. The pressure plate is a metal member bolted on the flywheel which houses the driven plate held in position by the transmission input shaft. A clutch sleeve mounted over the input shaft of the transmission carries a release bearing that is pressed against the fingers of the clutch that pushes it away from the driven plate causing disengagement-breaking the connection between the engine (flywheel) and the clutch. Reverse action or the release of the bearing engages the clutch. The release lever is actuated by a hydraulic system. Other internal clutch parts are a pilot bearing mounted in the crankshaft which supports the end of the input shaft. Bearings are designed for long life and require no lubrication. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > With Warner Transmission Clutch Disc: Service and Repair With Warner Transmission Single-Disc-Type Clutch Standard Disc and Pressure Plate Assembly10.0 lnch/11.0 lnch/12.0 Inch Removal 1. Disconnect the battery negative cable. 2. Remove clutch slave cylinder, or the hydraulic line quick disconnect using quick disconnect tool T88T-70522-A. 3. Remove the release lever if so equipped. 4. Remove the dust cover it so equipped. 5. Remove transmission. 6. Mark the assembled position of the pressure plate and cover to the flywheel (for re-assembly). 7. Remove the pressure plate and cover assembly and the clutch disc from the flywheel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > With Warner Transmission > Page 4368 Installation 1. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft D79T-7550-A or equivalent can enter the clutch pilot bearing and align the disc. 2. When re-installing the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. Position the pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Tighten the bolts to specification and remove the clutch disc pilot tool. 3. Clean and lubricate the release lever pivot stud. 4. Reinstall the transmission. 5. Correctly position the release lever (if so equipped) in its release bearing hub, and align with the pivot stud. Push inward on the lever until it snaps into position. 6. Reinstall the external slave cylinder, or attach the hydraulic tube quick connect fitting. 7. Install the dust boot if so equipped. 8. Install the starter motor. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > With Warner Transmission > Page 4369 Clutch Disc: Service and Repair Without Warner Transmission Single-Disc-Type Clutch Standard Disc and Pressure Plate Assembly10.0 lnch/11.0 lnch/12.0 Inch Removal 1. Disconnect the battery negative cable. 2. Remove clutch slave cylinder, or the hydraulic line quick disconnect using quick disconnect tool T88T-70522-A. 3. Remove the release lever if so equipped. 4. Remove the dust cover it so equipped. 5. Remove transmission. 6. Mark the assembled position of the pressure plate and cover to the flywheel (for re-assembly). 7. Remove the pressure plate and cover assembly and the clutch disc from the flywheel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > With Warner Transmission > Page 4370 Installation 1. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft D79T-7550-A or equivalent can enter the clutch pilot bearing and align the disc. 2. When re-installing the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. Position the pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Tighten the bolts to specification and remove the clutch disc pilot tool. 3. Clean and lubricate the release lever pivot stud. 4. Reinstall the transmission. 5. Correctly position the release lever (if so equipped) in its release bearing hub, and align with the pivot stud. Push inward on the lever until it snaps into position. 6. Reinstall the external slave cylinder, or attach the hydraulic tube quick connect fitting. 7. Install the dust boot if so equipped. 8. Install the starter motor. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Adjustments Clutch Pedal Assembly: Adjustments No clutch linkage or pedal travel adjustments are required. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > With Warner Transmission Pressure Plate: Service and Repair With Warner Transmission Single-Disc-Type Clutch Standard Disc and Pressure Plate Assembly10.0 lnch/11.0 lnch/12.0 Inch Removal 1. Disconnect the battery negative cable. 2. Remove clutch slave cylinder, or the hydraulic line quick disconnect using quick disconnect tool T88T-70522-A. 3. Remove the release lever if so equipped. 4. Remove the dust cover it so equipped. 5. Remove transmission. 6. Mark the assembled position of the pressure plate and cover to the flywheel (for re-assembly). 7. Remove the pressure plate and cover assembly and the clutch disc from the flywheel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > With Warner Transmission > Page 4381 Installation 1. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft D79T-7550-A or equivalent can enter the clutch pilot bearing and align the disc. 2. When re-installing the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. Position the pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Tighten the bolts to specification and remove the clutch disc pilot tool. 3. Clean and lubricate the release lever pivot stud. 4. Reinstall the transmission. 5. Correctly position the release lever (if so equipped) in its release bearing hub, and align with the pivot stud. Push inward on the lever until it snaps into position. 6. Reinstall the external slave cylinder, or attach the hydraulic tube quick connect fitting. 7. Install the dust boot if so equipped. 8. Install the starter motor. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > With Warner Transmission > Page 4382 Pressure Plate: Service and Repair Without Warner Transmission Single-Disc-Type Clutch Standard Disc and Pressure Plate Assembly10.0 lnch/11.0 lnch/12.0 Inch Removal 1. Disconnect the battery negative cable. 2. Remove clutch slave cylinder, or the hydraulic line quick disconnect using quick disconnect tool T88T-70522-A. 3. Remove the release lever if so equipped. 4. Remove the dust cover it so equipped. 5. Remove transmission. 6. Mark the assembled position of the pressure plate and cover to the flywheel (for re-assembly). 7. Remove the pressure plate and cover assembly and the clutch disc from the flywheel. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair > With Warner Transmission > Page 4383 Installation 1. Position the clutch disc on the flywheel so that the Clutch Alignment Shaft D79T-7550-A or equivalent can enter the clutch pilot bearing and align the disc. 2. When re-installing the original pressure plate and cover assembly, align the assembly and flywheel according to the marks made during the removal operations. Position the pressure plate and cover assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten the assembly to the flywheel. Tighten the bolts to specification and remove the clutch disc pilot tool. 3. Clean and lubricate the release lever pivot stud. 4. Reinstall the transmission. 5. Correctly position the release lever (if so equipped) in its release bearing hub, and align with the pivot stud. Push inward on the lever until it snaps into position. 6. Reinstall the external slave cylinder, or attach the hydraulic tube quick connect fitting. 7. Install the dust boot if so equipped. 8. Install the starter motor. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Testing and Inspection > Bearing Cups > Page 4390 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Testing and Inspection > Bearing Cups > Page 4391 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 4398 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 4399 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4404 Differential Axle Housing: Service and Repair Ford Integral Carrier Axle Disassembly, Ford Integral Carrier Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4405 Fig. 1 Disassembled view of Ford 6 3/4 inch ring gear axle Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4406 Fig. 2 Disassembled view of Ford 7 1/2 inch ring gear axle Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4407 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4408 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4409 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4414 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications TYPE: Standard 90 HP Limited-Slip 90 HP* 8.8" & 10 1/4" has removable cover, 9.0" does not CAPACITY, Refill: Front: Dana 44 3.8 pt (US) LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Label on door lock pillar shows letter and number Dana 50 4.0 pt (US) Dana 60 5.8 pt (US) Rear: Ford w/8.8" ring gear* 5.5 pt (US) 10 1/4 ring gear* 6.5 pt (US) Dana 60 & 61 6.0 pt (US) Dana 70 HD 7.4 pt (US) Dana 70 6.5 pt (US) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4417 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 4422 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 4423 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 4424 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 4425 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Page 4426 Pinion Bearing: Adjustments Fig. 4 Shim replacement for preload adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Page 4427 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4430 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4431 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4432 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4433 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4434 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4435 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4436 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Page 4441 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check > Page 4444 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check > Page 4445 Pinion Gear: Adjustments Pinion Bearing Preload & Final Depth Check Fig. 4 Shim replacement for preload adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check > Page 4446 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4449 Fig. 4 Shim replacement for preload adjustment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4450 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4451 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4452 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4453 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4454 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4455 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Testing and Inspection > Gears > Page 4460 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Adjustments > Assembly of Differential Into Housing > Page 4463 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 4469 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 4470 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4476 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 (V8-302 5.0L (1985)) 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 4477 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments > Page 4484 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH Technical Service Bulletin # 88717033088 Date: 880301 Vehicle - Body Boom Between 35 and 65 MPH VIBRATION - DRIVELINE - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE NOISE - "BODY BOOM" - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE Article No. 88-7-17 LIGHT TRUCK: 1983-87 E-150 ISSUE: "Body boom" and driveline vibration between the speeds of 35 and 65 mph (56 and 105 km/h) may be caused by one or more vehicle component areas. The vibration and boom are usually more noticeable when the AOD transmission is operating in overdrive, but may also occur when the AOD transmission is operating in third gear. In most cases there is more than one factor causing the NVH concern. ACTION: To correct this, use the following diagnostic procedures and the 1987 Light Truck Shop Manual, Section 18-01 to determine which vehicle components require attention. The diagnostic procedures should be followed in the order in which they appear in this TSB article. After the completion of each section the vehicle should be road tested to determine if the condition has been corrected. If the condition is still present, proceed to the next section. An Econoline NVH diagnostic chart is on page 52 of this TSB to assist in concern identification. Wheels & Tires, Chassis Groundout & Exhaust System Wheels and Tires 1. Make sure the front wheels are centered on the rotor hub pilot and the rear wheels are centered on the rear drum pilot by using the Rotunda Runout Gauge, 007-00014 to check wheel and tire assembly runout. NOTE: Special attention should be given to vehicles equipped with aftermarket aluminum wheels. 2. If incorrect wheel and tire assembly runout is found, loosen the lug nuts, rotate the wheel and tire assembly and carefully retighten the lug nuts finger tight. 3. Recheck the wheel and tire assembly runout while rotating the wheel and tire assembly. If the runout is okay, torque the lug nuts to 100 ft.lbs. (136 N-m). If runout is still incorrect, service as required. Body to Chassis Groundout 1. Raise the vehicle on a hoist and make sure the mounting bolts from aftermarket seats and safety belt anchors are not grounded to the frame, service as required. 2. Check to make sure the running boards are not grounded to the frame, service as required. 3. Make sure the exhaust system is not grounded to the frame, service as required. Exhaust System 1. Check to make sure an exhaust bind-up condition is not present by using the following steps: a. Road test the vehicle to determine if a "drone" noise is present each time the transmission shifts from one gear to the next between 0 and 65 MPH (0 and 105 km/h). b. If "drone" noise is present, apply the parking brake, depress the brake pedal and brake torque engine to simulate condition. The "drone" should appear around 1800 to 2000 RPM. c. Remove the exhaust system hanger in front and behind the muffler. d. Repeat Step b. If "drone" is gone, loosen the "Y" pipe at the exhaust manifold and the muffler. e. Reposition the exhaust system upward to eliminate stress on the two (2) hangers. Retighten the "Y" pipe to specification. NOTE: On 1987 vehicles, remove the front hanger bracket from the cross member. Knock out the existing retainer bolts from the hanger. Reinstall the bracket with longer bolts and add 1/4" to 1/2" stack of washers to each bolt between the bracket and cross member. This will make sure the rubber isolator is in a neutral position. Driveshaft & Road Test Procedure Information Driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 4494 1. Make sure the driveshaft runout does not exceed .035". Refer to the Light Truck Shop Manual, Section 18-01-8. 2. If runout exceeds .035", install a new driveshaft. Refer to the driveshaft application chart on page 49 of this TSB for the correct service part number. 3. Make sure the drive shaft U-joints are not worn. Check for a hard to move U-joint or a U-joint that catches when moved from side to side. NOTE: If it is necessary to replace a U-joint, refer to the following "Road Test" procedure to make sure a driveshaft imbalance is not caused by the U-joint replacement. 4. If the U-joints are okay, mark the driveshaft-to-axle flange with paint to aid in re-indexing. 5. Remove the driveshaft from the axle flange and re-index 180 degrees. 6. Road test the vehicle. NOTE: If the noise and vibration are still present or not acceptable, proceed to the "Road Test" procedure below. Road Test Procedure 1. Select a road where the vehicle can be safely operated at speeds from 25 to 65 MPH (40 to 105 km/h). 2. Slowly accelerate from 25 to 65 MPH (40 to 105 km/h) and observe the speed where the noise and vibration occur. Carefully watch the 35 to 45 MPH (56 to 72 km/h) range. 3. Shift into neutral at 65 MPH (105 km/h) and coast down to 25 MPH (40 km/h) noting at what speed the noise and vibration occur. ^ If the noise and vibration were not present during coast down, the NVH concern is not with an imbalanced driveshaft. ^ Vibrations during a neutral coastdown from 65 to 45 MPH (105 to 72 km/h) indicate an imbalanced driveshaft and/or imbalanced wheel and tire assemblies. ^ Vibrations from 35 to 45 MPH (56 to 72 km/h) indicate an imbalanced driveshaft. ^ Vibration from improperly balanced wheel and tire assemblies are normally FELT in the steering wheel and seats and do not have body "boom" noise associated with it. If this is the case, balance all four (4) wheel and tire assemblies. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 4495 ^ An improperly balanced driveshaft will usually have an audible noise or body "boom" noise. If this is the case, balance or replace the driveshaft. Driveshaft Balance & Rear Springs & Axle Information Driveshaft Balance 1. Raise the vehicle on a twin post hoist. 2. Start the engine, engage the transmission and run up to vibration speed. NOTE: Observe the level of vibration in the seat and steering wheel. 3. Have an assistant install one hose clamp at the rear of the driveshaft. Position the clamp with the screw head lined up with the existing balance weights on the driveshaft. 4. Start engine and run up to vibration speed. If the vibration got worse, rotate the clamp 180 degrees. Continue the procedure of rotating at 90 degree increments until all four (4) quadrants have been evaluated. Choose the best position and tighten clamp. 5. If vibration is still present, install a second clamp in the same position as the one installed in Step 4. 6. If vibration increases, scribe a line on the driveshaft at the screwhead locations. 7. Rotate one (1) clamp a 1/2" clockwise and the other 1/2" counterclockwise. Move the clamps further apart or closer together as required to "FINE TUNE" the system. Rear Springs 1. Make sure rear springs are the six leaf design. 2. If not, install two (2) new six leaf springs, (D6UZ-5560-D). Rear Axle 1. If the condition is still present after all the above sections have been completed, road test the vehicle to determine if the correct driveline angle is present or a new ring and pinion assembly is required. 2. Drive vehicle about 10-12 miles (16-19 kilometers). 3. With the transmission in overdrive for AOD transmission or in drive for C6 transmissions, accelerate to 50 MPH (80 km/h). Slowly increase the speed to 65 MPH (105 km/h) noting at what speed the noise and vibration occur. 4. Shift into neutral and coast down to 50 MPH (80 km/h). Observe whether or "boom" noise is present and at what speed. 5. If "boom" is only present in drive, measure the angle between the driveshaft and axle. If greater than 2 degrees, shim the axle at the spring seats to achieve a 1 degree angle. 6. Road test the vehicle. If the "boom" is still present, install a special "low" pitch line runout (PLRO) rear axle ring and pinion set. Refer to the following ring and pinion application chart. RING AND PINION APPLICATION CHART Axle Application Type Ratio Part Number 1983-86 9" 3.50:1 E3UZ-4209-D 1987 8.8" 3.55:1 E7TZ-4209-B NOTE: A new balanced half round circular flange, (E3UZ-4851-A) must be installed in 1983-86 units along with the 9" ring and pinion gear set. NOTE: A "boom" noise during a neutral coast indicates an imbalanced driveline. Refer back to the "Driveshaft Section" for diagnosis. PART NUMBER PART NAME CLASS E6UZ-4602-H Driveshaft C Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 4496 E6UZ-4602-J Driveshaft C E6UZ-4602-K Driveshaft C E7UZ-4602-U Driveshaft C E8UZ-4602-C Driveshaft C D6UZ-5560-D Rear Spring C E3UZ-4209-D Ring and Pinion C E7TZ-4209-B Ring and Pinion B E3UZ-4851-A Flange C OTHER APPLICABLE ARTICLES: 86-15-15 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Warranty Coverages OPERATION: 880717A - Wheel and Tire Section (Includes check runout and balance all four wheels and tire assemblies) TIME: 1.6 Hrs. OPERATION: 880717B - Body to Chassis Groundout Section TIME: 0.2 Hr. OPERATION: 880717C - Exhaust System Section TIME: 0.5 Hr. OPERATION: 880717D - Driveshaft and Road Test Sections TIME: 1.1 Hrs. OPERATION: 880717F - Driveshaft Balance Section TIME: 1.4 Hrs. OPERATION: 880717G - Rear Spring Section TIME: 1.4 Hrs. - Both OPERATION: 880717H - Rear Axle Section TIME: 3.5 Hrs. - Standard Axle 4.4 Hrs. - Limited Slip Axle DLR. CODING: Basic Condition Part No.: Code: Wheel and Tire Section 1007 67 Body to Chassis Groundout Section 7000396 35 Exhaust System Section 5260 36 Driveshaft and Road Test Sections 4602 67 Driveshaft Balance Section 4602 67 Rear Spring Section 5560 53 Rear Axle Section 4209 53 NOTE: The only components that are eligible under Powertrain Coverage are part numbers 4209 and 4602. Econoline Nvh Diagnosis Chart Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 4497 NOTE: If the complaint unit is a conversion van, be sure to raise vehicle on a hoist and inspect the second seat attachments to verify that the bolts are not too long and grounded to the frame cross member or other components. Also, check running board hangers to make certain that the hangers are not attached to the frame. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest: > 88417 > Feb > 88 > Driveline - Vibration/Boom Noise In Overdrive Propeller Shaft: Customer Interest Driveline - Vibration/Boom Noise In Overdrive ^ DRIVELINE - VIBRATION AND "BOOM" NOISE-VEHICLES WITH TWO-PIECE STEEL DRIVESHAFT ^ VIBRATION - "BOOM" NOISE - VEHICLES WITH TWO-PIECE STEEL DRIVESHAFT Article No. 88-4-17 LIGHT TRUCK: 1983-86 E-150, F-150 ISSUE: A driveline vibration and "booming" noise at 45-65 mph (72-105 km/h) with the transmission in overdrive may be caused by the two (2) piece steel driveshaft assembly. The affected Econolines are units built before 10/10/85 with a 138 inch wheelbase, 4.9L or 5.0L engine, AOD transmission, and 9 inch rear axle. The affected F-Series are F-150 4 x 2 units with a 133 inch wheelbase, 5.0L engine, AOD transmission and an 8.8 inch rear axle. ACTION: To correct this, install a new onepiece aluminum driveshaft using the following service procedure. Refer to the driveshaft application chart on this page for the correct service part. 1. Remove the existing two (2) piece steel driveshaft. 2. Install the appropriate tool in the transmission extension housing to prevent fluid leakage. 3. Remove the driveshaft center bearing support plate by chiseling off the rivet heads. The center bearing support plate must be removed to allow clearance for the new aluminum driveshaft. CAUTION: DO NOT drill or use a cutting torch to remove the rivets. This could damage the crossmember. 4. If the axle pinion flange lugs are damaged, replace the flange. 5. Lubricate the slip yoke splines with Ford Long Life Lubricant (C1AZ-19590-BA). 6. Remove the tool from the transmission extension housing. CAUTION: Never replace a two (2) piece STEEL driveshaft with a one (1) piece STEEL driveshaft. 7. Install the slip yoke end of the new aluminum driveshaft on the transmission output shaft. Be careful not to bottom the slip yoke on the transmission output shaft. 8. Install the aluminum driveshaft to the rear axle flange. Make sure the yellow dot on the driveshaft and the yellow dot on the axle flange are aligned. If the yellow dots are not visible, the vehicle will have to be test driven to determine the best position. 9. Tighten the U-bolts evenly to prevent premature U-joint failure. Torque the nuts to 8-15 ft.lbs. (11-20 N-m). PART NUMBER PART NAME CLASS E7UZ-4602-U Driveshaft C E8TZ-4602-W Driveshaft C C1AZ-19590-BA Ford Long Life Lubricant B OTHER APPLICABLE ARTICLES: 87-2-28 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Coverages OPERATION: 880417A - Install driveshaft TIME: 0.8 Hr. OPERATION: 880417AS1 - Re-index driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest: > 88417 > Feb > 88 > Driveline - Vibration/Boom Noise In Overdrive > Page 4502 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 4R602 - Code: 67 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest: > 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest: > 861515 > Jul > 86 > Driveline - Noise/Vibration Propeller Shaft: Customer Interest Driveline - Noise/Vibration Article No. 86-15-15 VIBRATION/NOISE - DRIVELINE - REPLACEMENT OF TWO-PIECE DRIVESHAFT - 138" WB - VEHICLES WITH 4.9L/5.0L ENGINE WITH AOD TRANSMISSION, 5.8L ENGINE WITH C6 TRANSMISSION LIGHT TRUCK 1983-86 E150 Vibration/ noise concerns involving driveshaft vibration on the subject vehicles may be solved by replacing the standard two-piece driveshaft with a one-piece graphite driveshaft using the procedure outlined below. CAUTION: Never replace a two-piece driveline with a one-piece STEEL driveline as vehicle damage may result leaving vehicle inoperative. 1. Remove the existing two-piece driveshaft from the vehicle. 2. Remove the two-piece driveshaft center bearing support plate. Rivets are to be removed by chiseling off the heads. Drilling or the use of cutting torch may result in damage to the crossmember. NOTE: The support plate must be removed to prevent interference with the new driveshaft. 3. When installing the one-piece driveshaft, be sure that the yellow dots on the driveshaft and axle flange are aligned. If the yellow dot on the axle flange is not visible, the vehicle will have to be test driven to determine the best orientation. Tighten U-bolt nuts to 8-15 ft.lbs. Nuts must be retightened evenly and within the specified torque to prevent premature U-joint bearing failure. 4. Test drive vehicle to confirm fix. Composite Composite Composite 2 Piece Driveline Axle and Vehicle D/S D/S Color D/S Being Replaced Attachment Usage (4602) Code Length (Eng. Part No.)* Method AOD Part No. (7000) 1983-86 E6UZ-C P-B-P 72.8" E5UA-4K145-BA 9" with half round E6TP-CA or -CB E150 flange U-bolts (non-piloted slip yoke) 4.9L/5.0L 1986 E6UZ-E P-W-V 71.9" E6UA-4K145-BAA 9" with half round E6UP-AA or -AB E150 flange U-bolts (piloted slip yoke) 5.0L 1986 E6UZ-F P-V-P 71.6" E6UZ-4K145-BAB 9" with circular E6UP-AA or -AB E150 flange individual (piloted slip yoke) 5.0L bolts (4) 1983-86 E6UZ-G C6 transmission E150 5.8L NOTE: Part numbers on a stick-on label on both coupling shaft and driveshaft. PART NUMBER PART NAME CLASS E6UZ-4602-C Driveshaft C E6UZ-4602-E Driveshaft C E6UZ-4602-F Driveshaft C E6UZ-4602-G Driveshaft C OTHER APPLICABLE ARTICLES: Supersedes 85-22-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4602C86 - Install one-piece driveline TIME: 0.8 Hr. OPERATION: SP4602D86 - Extra time to reindex driveshaft TIME: 0.4 Hr. DLR. CODING: Basic Part No. 4602 - Code: 67 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH Technical Service Bulletin # 88717033088 Date: 880301 Vehicle - Body Boom Between 35 and 65 MPH VIBRATION - DRIVELINE - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE NOISE - "BODY BOOM" - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE Article No. 88-7-17 LIGHT TRUCK: 1983-87 E-150 ISSUE: "Body boom" and driveline vibration between the speeds of 35 and 65 mph (56 and 105 km/h) may be caused by one or more vehicle component areas. The vibration and boom are usually more noticeable when the AOD transmission is operating in overdrive, but may also occur when the AOD transmission is operating in third gear. In most cases there is more than one factor causing the NVH concern. ACTION: To correct this, use the following diagnostic procedures and the 1987 Light Truck Shop Manual, Section 18-01 to determine which vehicle components require attention. The diagnostic procedures should be followed in the order in which they appear in this TSB article. After the completion of each section the vehicle should be road tested to determine if the condition has been corrected. If the condition is still present, proceed to the next section. An Econoline NVH diagnostic chart is on page 52 of this TSB to assist in concern identification. Wheels & Tires, Chassis Groundout & Exhaust System Wheels and Tires 1. Make sure the front wheels are centered on the rotor hub pilot and the rear wheels are centered on the rear drum pilot by using the Rotunda Runout Gauge, 007-00014 to check wheel and tire assembly runout. NOTE: Special attention should be given to vehicles equipped with aftermarket aluminum wheels. 2. If incorrect wheel and tire assembly runout is found, loosen the lug nuts, rotate the wheel and tire assembly and carefully retighten the lug nuts finger tight. 3. Recheck the wheel and tire assembly runout while rotating the wheel and tire assembly. If the runout is okay, torque the lug nuts to 100 ft.lbs. (136 N-m). If runout is still incorrect, service as required. Body to Chassis Groundout 1. Raise the vehicle on a hoist and make sure the mounting bolts from aftermarket seats and safety belt anchors are not grounded to the frame, service as required. 2. Check to make sure the running boards are not grounded to the frame, service as required. 3. Make sure the exhaust system is not grounded to the frame, service as required. Exhaust System 1. Check to make sure an exhaust bind-up condition is not present by using the following steps: a. Road test the vehicle to determine if a "drone" noise is present each time the transmission shifts from one gear to the next between 0 and 65 MPH (0 and 105 km/h). b. If "drone" noise is present, apply the parking brake, depress the brake pedal and brake torque engine to simulate condition. The "drone" should appear around 1800 to 2000 RPM. c. Remove the exhaust system hanger in front and behind the muffler. d. Repeat Step b. If "drone" is gone, loosen the "Y" pipe at the exhaust manifold and the muffler. e. Reposition the exhaust system upward to eliminate stress on the two (2) hangers. Retighten the "Y" pipe to specification. NOTE: On 1987 vehicles, remove the front hanger bracket from the cross member. Knock out the existing retainer bolts from the hanger. Reinstall the bracket with longer bolts and add 1/4" to 1/2" stack of washers to each bolt between the bracket and cross member. This will make sure the rubber isolator is in a neutral position. Driveshaft & Road Test Procedure Information Driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 4516 1. Make sure the driveshaft runout does not exceed .035". Refer to the Light Truck Shop Manual, Section 18-01-8. 2. If runout exceeds .035", install a new driveshaft. Refer to the driveshaft application chart on page 49 of this TSB for the correct service part number. 3. Make sure the drive shaft U-joints are not worn. Check for a hard to move U-joint or a U-joint that catches when moved from side to side. NOTE: If it is necessary to replace a U-joint, refer to the following "Road Test" procedure to make sure a driveshaft imbalance is not caused by the U-joint replacement. 4. If the U-joints are okay, mark the driveshaft-to-axle flange with paint to aid in re-indexing. 5. Remove the driveshaft from the axle flange and re-index 180 degrees. 6. Road test the vehicle. NOTE: If the noise and vibration are still present or not acceptable, proceed to the "Road Test" procedure below. Road Test Procedure 1. Select a road where the vehicle can be safely operated at speeds from 25 to 65 MPH (40 to 105 km/h). 2. Slowly accelerate from 25 to 65 MPH (40 to 105 km/h) and observe the speed where the noise and vibration occur. Carefully watch the 35 to 45 MPH (56 to 72 km/h) range. 3. Shift into neutral at 65 MPH (105 km/h) and coast down to 25 MPH (40 km/h) noting at what speed the noise and vibration occur. ^ If the noise and vibration were not present during coast down, the NVH concern is not with an imbalanced driveshaft. ^ Vibrations during a neutral coastdown from 65 to 45 MPH (105 to 72 km/h) indicate an imbalanced driveshaft and/or imbalanced wheel and tire assemblies. ^ Vibrations from 35 to 45 MPH (56 to 72 km/h) indicate an imbalanced driveshaft. ^ Vibration from improperly balanced wheel and tire assemblies are normally FELT in the steering wheel and seats and do not have body "boom" noise associated with it. If this is the case, balance all four (4) wheel and tire assemblies. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 4517 ^ An improperly balanced driveshaft will usually have an audible noise or body "boom" noise. If this is the case, balance or replace the driveshaft. Driveshaft Balance & Rear Springs & Axle Information Driveshaft Balance 1. Raise the vehicle on a twin post hoist. 2. Start the engine, engage the transmission and run up to vibration speed. NOTE: Observe the level of vibration in the seat and steering wheel. 3. Have an assistant install one hose clamp at the rear of the driveshaft. Position the clamp with the screw head lined up with the existing balance weights on the driveshaft. 4. Start engine and run up to vibration speed. If the vibration got worse, rotate the clamp 180 degrees. Continue the procedure of rotating at 90 degree increments until all four (4) quadrants have been evaluated. Choose the best position and tighten clamp. 5. If vibration is still present, install a second clamp in the same position as the one installed in Step 4. 6. If vibration increases, scribe a line on the driveshaft at the screwhead locations. 7. Rotate one (1) clamp a 1/2" clockwise and the other 1/2" counterclockwise. Move the clamps further apart or closer together as required to "FINE TUNE" the system. Rear Springs 1. Make sure rear springs are the six leaf design. 2. If not, install two (2) new six leaf springs, (D6UZ-5560-D). Rear Axle 1. If the condition is still present after all the above sections have been completed, road test the vehicle to determine if the correct driveline angle is present or a new ring and pinion assembly is required. 2. Drive vehicle about 10-12 miles (16-19 kilometers). 3. With the transmission in overdrive for AOD transmission or in drive for C6 transmissions, accelerate to 50 MPH (80 km/h). Slowly increase the speed to 65 MPH (105 km/h) noting at what speed the noise and vibration occur. 4. Shift into neutral and coast down to 50 MPH (80 km/h). Observe whether or "boom" noise is present and at what speed. 5. If "boom" is only present in drive, measure the angle between the driveshaft and axle. If greater than 2 degrees, shim the axle at the spring seats to achieve a 1 degree angle. 6. Road test the vehicle. If the "boom" is still present, install a special "low" pitch line runout (PLRO) rear axle ring and pinion set. Refer to the following ring and pinion application chart. RING AND PINION APPLICATION CHART Axle Application Type Ratio Part Number 1983-86 9" 3.50:1 E3UZ-4209-D 1987 8.8" 3.55:1 E7TZ-4209-B NOTE: A new balanced half round circular flange, (E3UZ-4851-A) must be installed in 1983-86 units along with the 9" ring and pinion gear set. NOTE: A "boom" noise during a neutral coast indicates an imbalanced driveline. Refer back to the "Driveshaft Section" for diagnosis. PART NUMBER PART NAME CLASS E6UZ-4602-H Driveshaft C Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 4518 E6UZ-4602-J Driveshaft C E6UZ-4602-K Driveshaft C E7UZ-4602-U Driveshaft C E8UZ-4602-C Driveshaft C D6UZ-5560-D Rear Spring C E3UZ-4209-D Ring and Pinion C E7TZ-4209-B Ring and Pinion B E3UZ-4851-A Flange C OTHER APPLICABLE ARTICLES: 86-15-15 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Warranty Coverages OPERATION: 880717A - Wheel and Tire Section (Includes check runout and balance all four wheels and tire assemblies) TIME: 1.6 Hrs. OPERATION: 880717B - Body to Chassis Groundout Section TIME: 0.2 Hr. OPERATION: 880717C - Exhaust System Section TIME: 0.5 Hr. OPERATION: 880717D - Driveshaft and Road Test Sections TIME: 1.1 Hrs. OPERATION: 880717F - Driveshaft Balance Section TIME: 1.4 Hrs. OPERATION: 880717G - Rear Spring Section TIME: 1.4 Hrs. - Both OPERATION: 880717H - Rear Axle Section TIME: 3.5 Hrs. - Standard Axle 4.4 Hrs. - Limited Slip Axle DLR. CODING: Basic Condition Part No.: Code: Wheel and Tire Section 1007 67 Body to Chassis Groundout Section 7000396 35 Exhaust System Section 5260 36 Driveshaft and Road Test Sections 4602 67 Driveshaft Balance Section 4602 67 Rear Spring Section 5560 53 Rear Axle Section 4209 53 NOTE: The only components that are eligible under Powertrain Coverage are part numbers 4209 and 4602. Econoline Nvh Diagnosis Chart Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 4519 NOTE: If the complaint unit is a conversion van, be sure to raise vehicle on a hoist and inspect the second seat attachments to verify that the bolts are not too long and grounded to the frame cross member or other components. Also, check running board hangers to make certain that the hangers are not attached to the frame. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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: > 88417 > Feb > 88 > Driveline - Vibration/Boom Noise In Overdrive Propeller Shaft: All Technical Service Bulletins Driveline - Vibration/Boom Noise In Overdrive ^ DRIVELINE - VIBRATION AND "BOOM" NOISE-VEHICLES WITH TWO-PIECE STEEL DRIVESHAFT ^ VIBRATION - "BOOM" NOISE - VEHICLES WITH TWO-PIECE STEEL DRIVESHAFT Article No. 88-4-17 LIGHT TRUCK: 1983-86 E-150, F-150 ISSUE: A driveline vibration and "booming" noise at 45-65 mph (72-105 km/h) with the transmission in overdrive may be caused by the two (2) piece steel driveshaft assembly. The affected Econolines are units built before 10/10/85 with a 138 inch wheelbase, 4.9L or 5.0L engine, AOD transmission, and 9 inch rear axle. The affected F-Series are F-150 4 x 2 units with a 133 inch wheelbase, 5.0L engine, AOD transmission and an 8.8 inch rear axle. ACTION: To correct this, install a new onepiece aluminum driveshaft using the following service procedure. Refer to the driveshaft application chart on this page for the correct service part. 1. Remove the existing two (2) piece steel driveshaft. 2. Install the appropriate tool in the transmission extension housing to prevent fluid leakage. 3. Remove the driveshaft center bearing support plate by chiseling off the rivet heads. The center bearing support plate must be removed to allow clearance for the new aluminum driveshaft. CAUTION: DO NOT drill or use a cutting torch to remove the rivets. This could damage the crossmember. 4. If the axle pinion flange lugs are damaged, replace the flange. 5. Lubricate the slip yoke splines with Ford Long Life Lubricant (C1AZ-19590-BA). 6. Remove the tool from the transmission extension housing. CAUTION: Never replace a two (2) piece STEEL driveshaft with a one (1) piece STEEL driveshaft. 7. Install the slip yoke end of the new aluminum driveshaft on the transmission output shaft. Be careful not to bottom the slip yoke on the transmission output shaft. 8. Install the aluminum driveshaft to the rear axle flange. Make sure the yellow dot on the driveshaft and the yellow dot on the axle flange are aligned. If the yellow dots are not visible, the vehicle will have to be test driven to determine the best position. 9. Tighten the U-bolts evenly to prevent premature U-joint failure. Torque the nuts to 8-15 ft.lbs. (11-20 N-m). PART NUMBER PART NAME CLASS E7UZ-4602-U Driveshaft C E8TZ-4602-W Driveshaft C C1AZ-19590-BA Ford Long Life Lubricant B OTHER APPLICABLE ARTICLES: 87-2-28 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Coverages OPERATION: 880417A - Install driveshaft TIME: 0.8 Hr. OPERATION: 880417AS1 - Re-index driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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: > 88417 > Feb > 88 > Driveline - Vibration/Boom Noise In Overdrive > Page 4524 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 4R602 - Code: 67 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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: > 861515 > Jul > 86 > Driveline - Noise/Vibration Propeller Shaft: All Technical Service Bulletins Driveline - Noise/Vibration Article No. 86-15-15 VIBRATION/NOISE - DRIVELINE - REPLACEMENT OF TWO-PIECE DRIVESHAFT - 138" WB - VEHICLES WITH 4.9L/5.0L ENGINE WITH AOD TRANSMISSION, 5.8L ENGINE WITH C6 TRANSMISSION LIGHT TRUCK 1983-86 E150 Vibration/ noise concerns involving driveshaft vibration on the subject vehicles may be solved by replacing the standard two-piece driveshaft with a one-piece graphite driveshaft using the procedure outlined below. CAUTION: Never replace a two-piece driveline with a one-piece STEEL driveline as vehicle damage may result leaving vehicle inoperative. 1. Remove the existing two-piece driveshaft from the vehicle. 2. Remove the two-piece driveshaft center bearing support plate. Rivets are to be removed by chiseling off the heads. Drilling or the use of cutting torch may result in damage to the crossmember. NOTE: The support plate must be removed to prevent interference with the new driveshaft. 3. When installing the one-piece driveshaft, be sure that the yellow dots on the driveshaft and axle flange are aligned. If the yellow dot on the axle flange is not visible, the vehicle will have to be test driven to determine the best orientation. Tighten U-bolt nuts to 8-15 ft.lbs. Nuts must be retightened evenly and within the specified torque to prevent premature U-joint bearing failure. 4. Test drive vehicle to confirm fix. Composite Composite Composite 2 Piece Driveline Axle and Vehicle D/S D/S Color D/S Being Replaced Attachment Usage (4602) Code Length (Eng. Part No.)* Method AOD Part No. (7000) 1983-86 E6UZ-C P-B-P 72.8" E5UA-4K145-BA 9" with half round E6TP-CA or -CB E150 flange U-bolts (non-piloted slip yoke) 4.9L/5.0L 1986 E6UZ-E P-W-V 71.9" E6UA-4K145-BAA 9" with half round E6UP-AA or -AB E150 flange U-bolts (piloted slip yoke) 5.0L 1986 E6UZ-F P-V-P 71.6" E6UZ-4K145-BAB 9" with circular E6UP-AA or -AB E150 flange individual (piloted slip yoke) 5.0L bolts (4) 1983-86 E6UZ-G C6 transmission E150 5.8L NOTE: Part numbers on a stick-on label on both coupling shaft and driveshaft. PART NUMBER PART NAME CLASS E6UZ-4602-C Driveshaft C E6UZ-4602-E Driveshaft C E6UZ-4602-F Driveshaft C E6UZ-4602-G Driveshaft C OTHER APPLICABLE ARTICLES: Supersedes 85-22-26 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP4602C86 - Install one-piece driveline TIME: 0.8 Hr. OPERATION: SP4602D86 - Extra time to reindex driveshaft TIME: 0.4 Hr. DLR. CODING: Basic Part No. 4602 - Code: 67 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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: > 851024 > May > 85 > Driveshaft - Handling Precautions Propeller Shaft: All Technical Service Bulletins Driveshaft - Handling Precautions Article No. 85-10-24 DRIVESHAFT, GRAPHITE AND ALUMINUM - HANDLING PRECAUTIONS LIGHT TRUCK 1984-85 LIGHT TRUCKS Some 1984-1/2, 1985 and 1986 Light Trucks including E Series Vans and (1986) Aerostar Vans are equipped with graphite or aluminum driveshafts. Under no circumstances are graphite or aluminum driveshafts to be clamped in the jaws of a vise or similar holding fixture. Denting or localized fracture of the tube may result which could cause driveshaft failure during vehicle operation. Place the driveshaft on a suitable work bench being careful not to damage the tube when performing U-joint or yoke replacement. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Propeller Shaft: > 851024 > May > 85 > Driveshaft - Handling Precautions Propeller Shaft: All Technical Service Bulletins Driveshaft - Handling Precautions Article No. 85-10-24 DRIVESHAFT, GRAPHITE AND ALUMINUM - HANDLING PRECAUTIONS LIGHT TRUCK 1984-85 LIGHT TRUCKS Some 1984-1/2, 1985 and 1986 Light Trucks including E Series Vans and (1986) Aerostar Vans are equipped with graphite or aluminum driveshafts. Under no circumstances are graphite or aluminum driveshafts to be clamped in the jaws of a vise or similar holding fixture. Denting or localized fracture of the tube may result which could cause driveshaft failure during vehicle operation. Place the driveshaft on a suitable work bench being careful not to damage the tube when performing U-joint or yoke replacement. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 4558 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4561 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 (V8-302 5.0L (1985)) 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 4562 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 (V8-302 5.0L (1985)) 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 4563 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > Customer Interest for Flex Plate: > 92186 > Aug > 92 > Engine - Metal to Metal Noise Flex Plate: Customer Interest Engine - Metal to Metal Noise Article No. 92-18-6 08/26/92 ^ ENGINE - 5.0L - THRUST BEARING OR CRANKSHAFT PREMATURE WEAR - VEHICLES WITH AOD TRANSMISSION ^ NOISE - "METAL-TO-METAL" SOUND - 5.0L WITH AOD TRANSMISSION ^ TRANSMISSION - AOD - INTERFERENCE BETWEEN THE TORQUE CONVERTER AND THE FLYWHEEL BOLTS FORD: 1982-88 THUNDERBIRD 1982-90 MUSTANG 1986 LTD 1987-90 CROWN VICTORIA LINCOLN-MERCURY: 1982-87 CAPRI, CONTINENTAL 1982-88 COUGAR 1982-90 TOWN CAR 1984-90 MARK VII 1987-90 GRAND MARQUIS LIGHT TRUCK: 1982-90 BRONCO, E-150, E-250, F-150, F-250 This TSB article is being republished in its entirety to include the 1982-1987 Continental and the 1982-1990 Town Car. ISSUE: An unusual "metal-to-metal" noise from the engine may be caused by the flexing of the torque converter. The flexing condition causes an interference between the torque converter and flywheel bolts. The interference can cause the thrust bearing and the crankshaft to wear prematurely and eventually fail. ACTION: Install six (6) new flywheel bolts with reduced head height to provide additional clearance. Refer to the appropriate Shop Manual, 5.0L Engine Section, for service details. NOTE: WHEN A CRANKSHAFT IS REPLACED DUE TO THRUST BEARING FAILURE, INSTALL A NEW CRANKSHAFT THAT HAS A REVISED PILOT HOLE. THIS WILL PROVIDE ADDITIONAL CLEARANCE FOR THE TOROUE CONVERTER. USE NEW FLYWHEEL BOLTS. PART NUMBER Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > Customer Interest for Flex Plate: > 92186 > Aug > 92 > Engine - Metal to Metal Noise > Page 4572 Operation Description Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Flex Plate: > 92186 > Aug > 92 > Engine - Metal to Metal Noise Flex Plate: All Technical Service Bulletins Engine - Metal to Metal Noise Article No. 92-18-6 08/26/92 ^ ENGINE - 5.0L - THRUST BEARING OR CRANKSHAFT PREMATURE WEAR - VEHICLES WITH AOD TRANSMISSION ^ NOISE - "METAL-TO-METAL" SOUND - 5.0L WITH AOD TRANSMISSION ^ TRANSMISSION - AOD - INTERFERENCE BETWEEN THE TORQUE CONVERTER AND THE FLYWHEEL BOLTS FORD: 1982-88 THUNDERBIRD 1982-90 MUSTANG 1986 LTD 1987-90 CROWN VICTORIA LINCOLN-MERCURY: 1982-87 CAPRI, CONTINENTAL 1982-88 COUGAR 1982-90 TOWN CAR 1984-90 MARK VII 1987-90 GRAND MARQUIS LIGHT TRUCK: 1982-90 BRONCO, E-150, E-250, F-150, F-250 This TSB article is being republished in its entirety to include the 1982-1987 Continental and the 1982-1990 Town Car. ISSUE: An unusual "metal-to-metal" noise from the engine may be caused by the flexing of the torque converter. The flexing condition causes an interference between the torque converter and flywheel bolts. The interference can cause the thrust bearing and the crankshaft to wear prematurely and eventually fail. ACTION: Install six (6) new flywheel bolts with reduced head height to provide additional clearance. Refer to the appropriate Shop Manual, 5.0L Engine Section, for service details. NOTE: WHEN A CRANKSHAFT IS REPLACED DUE TO THRUST BEARING FAILURE, INSTALL A NEW CRANKSHAFT THAT HAS A REVISED PILOT HOLE. THIS WILL PROVIDE ADDITIONAL CLEARANCE FOR THE TOROUE CONVERTER. USE NEW FLYWHEEL BOLTS. PART NUMBER Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Flex Plate: > 92186 > Aug > 92 > Engine - Metal to Metal Noise > Page 4578 Operation Description Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4587 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4588 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4589 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Page 4590 Fluid - M/T: Specifications Type 1987 5-speed Mercon(R) Automatic Transmission Fluid All others 80W EP CAPACITY, Refill: 3-speed 3.5 pt (US) 4-speed ex. OD 7.0 pt (US) W/OD 4.5 pt (US) 5-speed 7.4 pt (US) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Mainshaft Bearing/Bushing, M/T > Component Information > Technical Service Bulletins > M/T - M40D New Mainshaft Bearings Mainshaft Bearing/Bushing: Technical Service Bulletins M/T - M40D New Mainshaft Bearings Article No. 85-4-35 TRANSMISSION - M40D/TOD - NEW MAIN BEARINGS LIGHT TRUCK 1985 ECONOLINE, F SERIES, BRONCO As of approximately November 19, 1984 production, top shift overdrive (TOD) and manual 4-speed overdrive transmissions (M40D) will incorporate slip fit maindrive bearings in place of current press fit maindrive bearings. These bearings are used on both the input and output shafts. The use of the slip fit bearings will make assembly and disassembly easier, eliminating the use of special tools for bearing removal and installation. In the past with the press fit main bearings if removal for any reason was necessary, the bearings were discarded and replaced with new ones due to the removal procedure. With the new slip fit bearings the only ones that will be replaced during assembly and disassembly are those that are found to be defective. The new bearings are manufactured by Koyo Seiko and are identified by an "SH" marking in the inner race. Also to identify this change, the model identification suffix will be advanced on the transmission service I.D. tag (such as RTS-AB will be RTS-AB1, etc.). PART NUMBER PART NAME CLASS E5TZ-7025-C Bearing A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4600 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 (V8-302 5.0L (1985)) 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 9.0 pt (US) Warner 1345 6.5 pt (US) Warner 1356 4.0 pt (US) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 4603 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > Engine Compartment Wiring Connector Service Hydraulic Control Assembly - Antilock Brakes: Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 4629 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 4630 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 4631 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal Brake Pad: Customer Interest Front Brakes - Premature Lining Wear/Hard Pedal Article No. 89-25-16 ^ BRAKES - FRONT - PREMATURE LINING WEAR ^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO SUSPENSION MODIFICATION LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350 ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket suspension modifications. The modified suspension may affect the performance of the height sensing proportioning valve. Figure 2 Figure 3 ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear suspension (springs) to the suspension specifications Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4640 shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label, Figure 2 and 3. If the suspension has been modified or will be modified, use the following procedure. If the suspension has not been modified, replace the height sensing proportioning valve as outlined in TSB 88-12-20. Figure 1 1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly, Figure 1. Save the nut. 2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket, Figure 1. 3. Return the linkage to the customer. Figure 4 4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the bottom and parallel with the ground, Figure 3. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4641 Figure 5 5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5. Figure 6 6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6. Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated over the valve casting. 7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut to a torque of 8-10 lb.ft. (11-14 N-m). 8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows: "HSPV REAR BRAKE OPERATION MODIFIED". Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4642 Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E9TZ-2W125-A Valve Shaft Positioner C OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892516A Modify Height Sensing 0.6 Hr. Valve DEALER CODING BASIC PART NO. CONDITION CODE 2B547 53 OASIS CODES: 3050, 3051 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest: > 86813 > Apr > 86 > Front Disc Brakes - Squealing Noise Brake Pad: Customer Interest Front Disc Brakes - Squealing Noise Article No. 86-8-13 BRAKES - FRONT DISC - SQUEAL LIGHT TRUCK 1980-86 E100/350, F100/350, BRONCO If the subject vehicles are experiencing a brake squeal concern, they should be serviced by installing insulator pads. Information in TSB 85-3-10 should not be used, this new service action supersedes the previous article with updated information. The following procedures and precautions should be observed when servicing front brake squeal concerns. ^ Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coating of ESAM1C172-A(D7AZ-19590-A) lubricant to both surfaces. Be careful not to get lube on rotors or linings. Wipe any excess lube off after assembly. Visually inspect rotors for any obvious damage or scoring. ^ Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the procedures included in the Light Truck Shop Manual, Sections 11-10 and 11-12. NOTE: The disc brake caliper and pads must be removed from the spindle prior to adjusting the front wheel bearings. ^ Clean lining and rotor surfaces. Remove any uneven glaze buildup on lining and rotor braking surfaces by sanding with medium to fine sandpaper or emery cloth. Uniform rotor sanding can be accomplished by holding the paper against the rotor braking surface while manually turning the rotor. ^ Remove any loose insulator material from the pad backing plates with sandpaper or an appropriate solvent. This procedure applies only to the following models: 1980-86 E100/150, F100/150, Bronco, F250 4x2 under 6900 lbs. GVW (single piston calipers). ^ Install the service insulator (E1TZ-2B321-A) to the backing plate of the OUTBOARD pad and lining assembly (both L.H. and R.H. brake). Bond the insulator to the back side of the brake pad assembly with ESA-M1C140-A1 (D7AZ-19554-C) adhesive. Apply adhesive to the light color side of each insulator. Assure that insulator is centered on backing plate and that directions for applying adhesive are followed. This procedure is for 1980-86 F250 4x2 over 6900 lbs. GVW, F250 4x4, F350, E250/350 (dual piston calipers). ^ Install the service insulator (E1TZ-2B321-B) to the back side of the INBOARD pad and lining assembly (both L.H. and R.H. brake). Bond the insulator to the backing plate and lining assembly using the previously listed procedure. ^ Install the service shim (E6TZ-2B321-A) to the back side of the outboard pad and lining assembly (both L.H. and R.H. brake) by clipping the shim over the straight edge of the backing plate. Be sure the shim is fully seated and centered on the straight edge of the backing plate. NOTE: For dual piston caliper application only. ^ Reinstall caliper to the spindle assembly. NOTE: DO NOT replace linings unless required for wear or additional concerns (Shop Manual, Section 12-24). PART NUMBER PART NAME CLASS E1TZ-2B321-A Insulator BM E1TZ-2B321-B Insulator BM E6TZ-2B321-A Shim B D7AZ-19590-A Lubricant A D7AZ-19554-C Adhesive AM OTHER APPLICABLE ARTICLES: Supersedes 85-3-10 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2321A86A - 1980-85 TIME: 1.1 Hrs. OPERATION: SP2321A86B - 1986 TIME: 1.0 Hr. DLR. CODING: Basic Part No. 2001 - Code: 56 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 90226 > Oct > 90 > Brakes - Intermittent Brake Squeal Brake Pad: All Technical Service Bulletins Brakes - Intermittent Brake Squeal Article No. 90-22-6 ^ BRAKES - OCCASIONAL OR INTERMITTENT "SQUEAL" ^ NOISE - BRAKES - OCCASIONAL OR INTERMITTENT SQUEAL" FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER This TSB article is being republished in its entirety to expand the model and model year coverage. ISSUE: Occasional or intermittent brake squeal may be cause by the brake friction material generating noise and heat in order to dissipate energy. This occasional or intermittent squeal may be a normal condition and requires no corrective action. ACTION: If a customer is concerned about occasional or intermittent brake squeal, it should be explained that brake friction materials inherently generate noise and heat in order to dissipate energy. As a result, an occasional squeal condition may be normal, and could be affected by cold, heat, wetness, snow, salt, mud etc. NOTE: THIS OCCASIONAL OR INTERMITTENT SQUEAL IS NOT A FUNCTIONAL PROBLEM AND DOES NOT INDICATE ANY LOSS OF BRAKE EFFECTIVENESS. OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-16-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702000, 702100 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal Brake Pad: All Technical Service Bulletins Front Brakes - Premature Lining Wear/Hard Pedal Article No. 89-25-16 ^ BRAKES - FRONT - PREMATURE LINING WEAR ^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO SUSPENSION MODIFICATION LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350 ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket suspension modifications. The modified suspension may affect the performance of the height sensing proportioning valve. Figure 2 Figure 3 ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear suspension (springs) to the suspension specifications Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4656 shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label, Figure 2 and 3. If the suspension has been modified or will be modified, use the following procedure. If the suspension has not been modified, replace the height sensing proportioning valve as outlined in TSB 88-12-20. Figure 1 1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly, Figure 1. Save the nut. 2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket, Figure 1. 3. Return the linkage to the customer. Figure 4 4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the bottom and parallel with the ground, Figure 3. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4657 Figure 5 5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5. Figure 6 6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6. Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated over the valve casting. 7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut to a torque of 8-10 lb.ft. (11-14 N-m). 8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows: "HSPV REAR BRAKE OPERATION MODIFIED". Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4658 Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E9TZ-2W125-A Valve Shaft Positioner C OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892516A Modify Height Sensing 0.6 Hr. Valve DEALER CODING BASIC PART NO. CONDITION CODE 2B547 53 OASIS CODES: 3050, 3051 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Vehicle - Moaning/Droaning at 55 to 65 MPH Article No. 85-4-39 MOAN/DRONE (5.0L/5.8L) - 2100 2800 RPM LIGHT TRUCK 1983-85 ECONOLINE, F150-350, BRONCO A moan/drone condition encountered at 55-65 mph may be a 2100-2800 engine rpm-related condition. Diagnosis and servicing will require a good road test followed by servicing of: 1) engine mounting, 2) exhaust hanger, 3) alternator pulley, and 4) alternator/thermactor braces depending on vehicle model and engine combination. 1. Road Test & Service Engine Mountings a. Road test vehicle. The vehicle should be equipped with a portable tachometer and driven at a road speed of 55-65 MPH (engine speed of 2100-2800 RPM). The A/C system should be in the "off" position and the vehicle should be evaluated on a smooth surfaced road or highway. If the road test verifies a "drone/ moan" condition, then the following procedures should be followed: Figure 25 b. On Bronco and F150-350 vehicles, loosen the No. 3 crossmember/rear engine support gussets at the attachment to the crossmember. If the gussets pull away from the crossmember, add shims to the gap. Retighten mounting bolts (install larger bolts if required). Refer to attached Figure 25). c. On model F150-350 (4x2)/E150-350 vehicles, inspect rear engine insulator (mount) for correct usage of Engineering Part E3TA-6D091-A/Service Part E0TZ-6068-B (white color code). Install correct part if required. Inspect mount for correct orientation of "capture strap" which could bind up the mount. With the vehicle on a two-post hoist, neutralize the front and rear engine support insulators (front and rear engine mounts) by loosening the front and rear engine mounts attaching bolts (attaching front mounts to support bracket and the rear mount to the No. 3 crossmember. Lower the vehicle and place safety stands under the front and rear axles. Start the engine and shift the automatic transmission into "drive" and back into "neutral" several times while engine is idling. With manual transmission, load engine by shifting transmission into forward and reverse gears and, with the parking brake partially applied, slip the clutch to load the engine. Raise the vehicle and remove the axle stands. Retorque front and rear engine mount attaching bolts (refer to Section 21-21 of 1983-1984 Light Truck Shop Manual for torque specifications). Lower vehicle and remove from hoist. d. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 2. Double Link Exhaust Hanger Installation - F - 4 x 2 Models Only a. 1980-83 Vehicles Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4668 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4669 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4670 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4671 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4672 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4678 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4679 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4680 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4681 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4682 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 4683 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 4697 Brake Rotor/Disc: Specifications Front Nominal Thickness 1.19 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Installation > Page 4704 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Intermittent Brake Squeal Brake Shoe: Technical Service Bulletins Brakes - Intermittent Brake Squeal Article No. 90-22-6 ^ BRAKES - OCCASIONAL OR INTERMITTENT "SQUEAL" ^ NOISE - BRAKES - OCCASIONAL OR INTERMITTENT SQUEAL" FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER This TSB article is being republished in its entirety to expand the model and model year coverage. ISSUE: Occasional or intermittent brake squeal may be cause by the brake friction material generating noise and heat in order to dissipate energy. This occasional or intermittent squeal may be a normal condition and requires no corrective action. ACTION: If a customer is concerned about occasional or intermittent brake squeal, it should be explained that brake friction materials inherently generate noise and heat in order to dissipate energy. As a result, an occasional squeal condition may be normal, and could be affected by cold, heat, wetness, snow, salt, mud etc. NOTE: THIS OCCASIONAL OR INTERMITTENT SQUEAL IS NOT A FUNCTIONAL PROBLEM AND DOES NOT INDICATE ANY LOSS OF BRAKE EFFECTIVENESS. OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-16-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702000, 702100 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 4709 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 4712 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 4732 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 4733 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 4734 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Brake Fluid Pressure Sensor/Switch: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Technical Service Bulletins > Page 4739 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Technical Service Bulletins > Brake Hoses - Wet Appearance Brake Hose/Line: Technical Service Bulletins Brake Hoses - Wet Appearance Article No. 91-18-9 09/05/91 ^ BRAKES-HYDRAULIC-RUBBER BRAKE HOSES ARE WET FROM SWEATING ^ BRAKES-HYDRAULIC-RUBBER HOSES-FLUID LEAK TESTING PROCEDURE LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-92 AEROSTAR 1988-92 F SUPER DUTY, F-47, F-63, F-59 1991-92 EXPLORER This TSB article is being republished in its entirety to include 1992 model vehicles. ISSUE: The wet appearance of the outer cover of rubber brake hoses is called "sweating." This is a normal condition for neoprene rayon braid hose. The "sweating" condition is not evidence of a brake fluid leak and will not result in a loss of pressure in the system. ACTION: No action is required for a normal "sweating" brake hose. However, to test for a hydraulic fluid leak, proceed as follows: 1. Check the brake fluid level in the master cylinder. If necessary, add brake fluid. 2. Wipe off the hose(s) in question with a clean cloth and an all purpose cleaner, then dry. 3. With the engine running, fully depress the brake twice and hold for two (2) minutes. ^ If the pedal goes down, check all of the connections for leaks and repair as required. ^ If the pedal goes down and no visible leaks are seen, then the master cylinder is leaking internally and must be replaced or rebuilt. Refer to the appropriate Light Truck or Medium/Heavy Truck Shop Manual, Section 6 or 12 (Light Truck) and Section 12 (Med./Hvy Truck) for service details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-11-9 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal Brake Proportioning/Combination Valve: Customer Interest Front Brakes - Premature Lining Wear/Hard Pedal Article No. 89-25-16 ^ BRAKES - FRONT - PREMATURE LINING WEAR ^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO SUSPENSION MODIFICATION LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350 ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket suspension modifications. The modified suspension may affect the performance of the height sensing proportioning valve. Figure 2 Figure 3 ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear suspension (springs) to the suspension specifications Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4752 shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label, Figure 2 and 3. If the suspension has been modified or will be modified, use the following procedure. If the suspension has not been modified, replace the height sensing proportioning valve as outlined in TSB 88-12-20. Figure 1 1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly, Figure 1. Save the nut. 2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket, Figure 1. 3. Return the linkage to the customer. Figure 4 4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the bottom and parallel with the ground, Figure 3. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4753 Figure 5 5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5. Figure 6 6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6. Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated over the valve casting. 7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut to a torque of 8-10 lb.ft. (11-14 N-m). 8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows: "HSPV REAR BRAKE OPERATION MODIFIED". Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4754 Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E9TZ-2W125-A Valve Shaft Positioner C OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892516A Modify Height Sensing 0.6 Hr. Valve DEALER CODING BASIC PART NO. CONDITION CODE 2B547 53 OASIS CODES: 3050, 3051 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal Brake Proportioning/Combination Valve: All Technical Service Bulletins Front Brakes - Premature Lining Wear/Hard Pedal Article No. 89-25-16 ^ BRAKES - FRONT - PREMATURE LINING WEAR ^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO SUSPENSION MODIFICATION LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350 ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket suspension modifications. The modified suspension may affect the performance of the height sensing proportioning valve. Figure 2 Figure 3 ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear suspension (springs) to the suspension specifications Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4760 shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label, Figure 2 and 3. If the suspension has been modified or will be modified, use the following procedure. If the suspension has not been modified, replace the height sensing proportioning valve as outlined in TSB 88-12-20. Figure 1 1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly, Figure 1. Save the nut. 2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket, Figure 1. 3. Return the linkage to the customer. Figure 4 4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the bottom and parallel with the ground, Figure 3. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4761 Figure 5 5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5. Figure 6 6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6. Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated over the valve casting. 7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut to a torque of 8-10 lb.ft. (11-14 N-m). 8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows: "HSPV REAR BRAKE OPERATION MODIFIED". Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 4762 Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E9TZ-2W125-A Valve Shaft Positioner C OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892516A Modify Height Sensing 0.6 Hr. Valve DEALER CODING BASIC PART NO. CONDITION CODE 2B547 53 OASIS CODES: 3050, 3051 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Page 4763 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Hydraulic Control Assembly - Antilock Brakes: Technical Service Bulletins Engine Compartment Wiring - Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Technical Service Bulletins > Height Sensing Proportioning Valve - Service Procedure Load Compensator: Technical Service Bulletins Height Sensing Proportioning Valve - Service Procedure Article No. 85-21-14 BRAKE - VEHICLE HEIGHT SENSING PROPORTIONING VALVE SERVICE PROCEDURE LIGHT TRUCK 1985-86 F & E-250/350 All F & E-250/350 vehicies built after May 1, 1985 will be equipped with a brake height sensing valve. Figure 16 - Sensing Proportioning Valve/Service Procedure The valve is located on the number five crossmember and is activated through a linkage system that is connected to the axle housing cover of the rear axle assembly. See Figure 16. The following service procedure is recommended for removing and installing the valve assembly. 1. Raise vehicle on hoist and allow the rear suspension and rear axle to hang in full rebound position. (Rear shock absorbers, if so equipped, must be connected to the rear axle.) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel Brakes > Component Information > Technical Service Bulletins > Height Sensing Proportioning Valve - Service Procedure > Page 4772 2. Remove both rear wheels and tires. 3. Remove linkage assembly (2C193) from the valve (2B547). 4. Remove the brake hose (2282). 5. Remove valve (2B547) from mounting bracket (2B526) and replace with new valve (2B547). 6. Position and attach the sensing valve (2B547) to mounting bracket (2B526) with two bolts. Torque bolts to 14-22 ft.lbs. 7. Connect linkage assembly (2C193) to the sensing valve shaft. Squeeze the plastic bushing of the link assembly onto the serrated section of the valve shaft using large groove-joint type pliers. 8. Install nut (379930) securing link assembly to valve shaft. Torque nut to 8-10 ft.lbs. 9. Install rear brake hose assembly (2282) to the sensing valve (2B547) with the existing bolt (385116) and two new washers (388949). Torque bolt to 17-25 ft.lbs. 10. Bleed brake system and correct any leakage. 11. Install wheels and tires. 12. Lower vehicle. 13. Road test to confirm repair. NOTE: The valve will automatically become operational when the vehicle's suspension is in the "curb condition". When servicing other rear suspension components (axle assembly, rear springs, fuel tank, etc.), remove the two nuts attaching the sensing valve linkage (2C193)to the rear axle cover plate. This will eliminate the need to replace the brake valve. If the linkage assembly is disconnected from the height sensing valve, a new sensing valve must also be installed. NOTE: Any change to the vehicle rear suspension which will alter "curb" ride height (e.g. increased capacity leaf springs, addition of spacers, etc.) may change the function of the height sensing valve and alter the system braking performance. The new sensing valve assembly will have the shaft preset and secured internally. If the valve shaft of the valve turns freely - DO NOT USE. The height/load sensing brake proporting valve (2B547) is not to be repaired or disassembled. It must be replaced as a complete assembly. If the linkage assembly (2C193) is damaged or broken and requires replacement, a new sensing valve must also be installed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2547B85 TIME: 1.6 Hrs. DLR. CODING: Basic Part No. 2B547 - Code: 42 NOTE: Reimbursable under warranty only if the height sensing valve is defective. Height sensing valves replaced because of damaged or broken linkage assembly (2C193) are not reimbursable under warranty. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 4776 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 4777 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Adjustments Parking Brake Lever: Adjustments 1985---87 E-350 W/ORSCHEIN PARKING BRAKE LEVER 1. Place parking brake handle in ON position. 2. Grip tension limiter housing to prevent it from turning and tighten equalizer nut until front cable tension is 350 lbs. 3. Release, then reapply parking brake system and ensure front cable tension is at least 310 lbs. 4. Release parking brake and check for rear wheel drive. 5. If rear wheel drag is noted after adjustment, the rear drums must be removed after the service and parking brakes have been adjusted. Check clearance between parking brake lever and cam plate. If clearance is not .015 inch with brakes fully released, readjust parking brake cable. 6. Place parking brake in fully released position, then check slack in parking brake two rear cables. The cables should be tight enough to provide full application of the rear brake shoes when the parking brake lever or foot pedal is placed in the fully applied position, yet loose enough to ensure complete release of the brake shoes when the lever is in released position. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 4789 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Technical Service Bulletins > Engine Compartment Wiring Connector Service Brake Fluid Pressure Sensor/Switch: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Technical Service Bulletins > Page 4795 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 4812 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 4818 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Page 4819 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 4823 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations On RH front fender Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Battery Cable: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > Customer Interest for Alternator Pulley: > 85439 > Feb > 85 > Vehicle Moaning/Droaning at 55 to 65 MPH Alternator Pulley: Customer Interest Vehicle - Moaning/Droaning at 55 to 65 MPH Article No. 85-4-39 MOAN/DRONE (5.0L/5.8L) - 2100 2800 RPM LIGHT TRUCK 1983-85 ECONOLINE, F150-350, BRONCO A moan/drone condition encountered at 55-65 mph may be a 2100-2800 engine rpm-related condition. Diagnosis and servicing will require a good road test followed by servicing of: 1) engine mounting, 2) exhaust hanger, 3) alternator pulley, and 4) alternator/thermactor braces depending on vehicle model and engine combination. 1. Road Test & Service Engine Mountings a. Road test vehicle. The vehicle should be equipped with a portable tachometer and driven at a road speed of 55-65 MPH (engine speed of 2100-2800 RPM). The A/C system should be in the "off" position and the vehicle should be evaluated on a smooth surfaced road or highway. If the road test verifies a "drone/ moan" condition, then the following procedures should be followed: Figure 25 b. On Bronco and F150-350 vehicles, loosen the No. 3 crossmember/rear engine support gussets at the attachment to the crossmember. If the gussets pull away from the crossmember, add shims to the gap. Retighten mounting bolts (install larger bolts if required). Refer to attached Figure 25). c. On model F150-350 (4x2)/E150-350 vehicles, inspect rear engine insulator (mount) for correct usage of Engineering Part E3TA-6D091-A/Service Part E0TZ-6068-B (white color code). Install correct part if required. Inspect mount for correct orientation of "capture strap" which could bind up the mount. With the vehicle on a two-post hoist, neutralize the front and rear engine support insulators (front and rear engine mounts) by loosening the front and rear engine mounts attaching bolts (attaching front mounts to support bracket and the rear mount to the No. 3 crossmember. Lower the vehicle and place safety stands under the front and rear axles. Start the engine and shift the automatic transmission into "drive" and back into "neutral" several times while engine is idling. With manual transmission, load engine by shifting transmission into forward and reverse gears and, with the parking brake partially applied, slip the clutch to load the engine. Raise the vehicle and remove the axle stands. Retorque front and rear engine mount attaching bolts (refer to Section 21-21 of 1983-1984 Light Truck Shop Manual for torque specifications). Lower vehicle and remove from hoist. d. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 2. Double Link Exhaust Hanger Installation - F - 4 x 2 Models Only a. 1980-83 Vehicles Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > Customer Interest for Alternator Pulley: > 85439 > Feb > 85 > Vehicle Moaning/Droaning at 55 to 65 MPH > Page 4843 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > Customer Interest for Alternator Pulley: > 85439 > Feb > 85 > Vehicle Moaning/Droaning at 55 to 65 MPH > Page 4844 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > Customer Interest for Alternator Pulley: > 85439 > Feb > 85 > Vehicle Moaning/Droaning at 55 to 65 MPH > Page 4845 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > Customer Interest for Alternator Pulley: > 85439 > Feb > 85 > Vehicle Moaning/Droaning at 55 to 65 MPH > Page 4846 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > Customer Interest for Alternator Pulley: > 85439 > Feb > 85 > Vehicle Moaning/Droaning at 55 to 65 MPH > Page 4847 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator Pulley: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH Alternator Pulley: All Technical Service Bulletins Vehicle - Moaning/Droaning at 55 to 65 MPH Article No. 85-4-39 MOAN/DRONE (5.0L/5.8L) - 2100 2800 RPM LIGHT TRUCK 1983-85 ECONOLINE, F150-350, BRONCO A moan/drone condition encountered at 55-65 mph may be a 2100-2800 engine rpm-related condition. Diagnosis and servicing will require a good road test followed by servicing of: 1) engine mounting, 2) exhaust hanger, 3) alternator pulley, and 4) alternator/thermactor braces depending on vehicle model and engine combination. 1. Road Test & Service Engine Mountings a. Road test vehicle. The vehicle should be equipped with a portable tachometer and driven at a road speed of 55-65 MPH (engine speed of 2100-2800 RPM). The A/C system should be in the "off" position and the vehicle should be evaluated on a smooth surfaced road or highway. If the road test verifies a "drone/ moan" condition, then the following procedures should be followed: Figure 25 b. On Bronco and F150-350 vehicles, loosen the No. 3 crossmember/rear engine support gussets at the attachment to the crossmember. If the gussets pull away from the crossmember, add shims to the gap. Retighten mounting bolts (install larger bolts if required). Refer to attached Figure 25). c. On model F150-350 (4x2)/E150-350 vehicles, inspect rear engine insulator (mount) for correct usage of Engineering Part E3TA-6D091-A/Service Part E0TZ-6068-B (white color code). Install correct part if required. Inspect mount for correct orientation of "capture strap" which could bind up the mount. With the vehicle on a two-post hoist, neutralize the front and rear engine support insulators (front and rear engine mounts) by loosening the front and rear engine mounts attaching bolts (attaching front mounts to support bracket and the rear mount to the No. 3 crossmember. Lower the vehicle and place safety stands under the front and rear axles. Start the engine and shift the automatic transmission into "drive" and back into "neutral" several times while engine is idling. With manual transmission, load engine by shifting transmission into forward and reverse gears and, with the parking brake partially applied, slip the clutch to load the engine. Raise the vehicle and remove the axle stands. Retorque front and rear engine mount attaching bolts (refer to Section 21-21 of 1983-1984 Light Truck Shop Manual for torque specifications). Lower vehicle and remove from hoist. d. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 2. Double Link Exhaust Hanger Installation - F - 4 x 2 Models Only a. 1980-83 Vehicles Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator Pulley: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4853 Remove the intermediate exhaust hanger bracket assembly located at rear of the catalytic converter. Discard the hanger bracket assembly and install a new double link exhaust hanger bracket assembly. b. 1984-85 Vehicles 1. Remove the intermediate exhaust hanger bracket assembly located at the rear of the catalytic converter. Figure 23 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator Pulley: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4854 Figure 24 - Hanger Clearance 2. Rework a new double link hanger to fit: See Figure 23 and 24. a. remove lower portion of bracket b. drill new 8.7 - 9.2 mm bolt holes in bracket c. drill two new 8.7 - 9.2 mm mounting bolt holes in frame web. d. install bracket on frame using N605906-S2 bolt and (2) nuts N620481-S50. c. Re-road test to establish concern resolution. If concern is not resolved, continue procedure. 3. Alternator Drive Ratio Resolution: 5.8L - All Model Vehicles a. Remove 2.62" alternator pulley and replace with 2.75" pulley. b. Road test. If condition is still present, replace alternator pulley with 3.0" pulley. c. Road test. If concern is still present, continue with procedure. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator Pulley: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4855 Figure 26 - Reinforced Braces Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator Pulley: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4856 Figure 27 - Reinforced Braces 4. Addition of Alternator and Thermactor Pump Braces Inspect the engine to verify that an air pump brace and an alternator brace is installed on the front end accessory drive area (refer to Figure 26 for 5.0L engine and Figure 27 for 5.8L engine). If no braces are currently installed, install the braces per Figures 26 and 27. PART NUMBER PART NAME CLASS E0TZ-6068-B Mount - rear engine BM E0TZ-5A246-B Hanger - exhaust C double link C5AZ-10344-L Pulley - 2.75" duel shiv AG C5AZ-10344-K Pulley - 2.75" single shiv AG D2AZ-10344-A Pulley - 3.0" dual shiv CG D20Z-10344-A Pulley - 3.0" single shiv C E4TZ-9F492-A Brace - thermactor pump CG 5.0L Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Alternator Pulley: > 85439 > Feb > 85 > Vehicle - Moaning/Droaning at 55 to 65 MPH > Page 4857 E4TZ-10145-A Brace - alternator CG 5.0L large frame CG E4TZ-10145-B Brace - alternator CG 5.0L small frame E4TZ-9B450-B Brake - thermactor pump C 5.8L E4TZ-10N345-D Brace - alternator - C 5.8L small frame E4TZ-10N345-E Brace - alternator - C 5.8L large frame 390158-S36 Stud - 5.0L/5.8L S 57103-S36 Stud and washer - S 5.0L 388469-S Stud and washer - S 5.0L/5.8L 382802-S2 Flange nut - 5.0L BR 34977-S2 Nut - 5.0L S 34987-S100 Nut - 5.8L SG N620481-S50 Nut - exhaust hanger S N605906-S2 exhaust hanger BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: OPERATION SERVICE TIME SP6068A85 Road test and service engine mounts E 1.3 Hrs. F (4x2) 1.6 Hrs. F (4x4) 1.7 Hrs. SP6068B85 Replace exhaust hanger; rework exhaust hanger to fit 84/85 80-83 0.6 Hr. 84-85 1.0 Hr. SP6068C85 Replace alternator pulley - 5.8L (may be performed twice) .8 Hr. SP6068D85 Install braces on alternator and thermactor - 5.0L, 5.8L-2V E 0.7 Hr. F 0.6 Hr. DLR. CODING: Basic Part No. - Code to part involved in final step taken. Condition code as applicable. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Testing and Inspection Rectifier Diode / Bridge: Testing and Inspection Fig. 13 Testing diode trio Fig. 14 Alternator w/integral regulator rectifier short or grounded & stator grounded test RECTIFIER SHORT OR GROUNDED & STATOR GROUNDED TEST Using a suitable ohmmeter, connect one probe to the alternator BAT terminal, Figs. 13 and 14, and the other probe to the STA terminal (rear blade terminal). Then, reverse the ohmmeter probes and repeat the test. A reading of about 6.5 ohms should be obtained in one direction and no needle movement with the probes reversed. A reading in both directions indicates a bad positive diode, a grounded positive diode plate or a grounded BAT terminal. Perform the same test using the STA and GND (ground) terminals of the alternator. A reading in both directions indicates either a bad negative diode, a grounded stator winding, a grounded stator terminal, a grounded positive diode plate, or a grounded BAT terminal. Infinite readings (no needle movement) in all four probe positions in the preceding tests indicates an open STA terminal lead connection inside the alternator. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Testing and Inspection > Page 4864 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Testing and Inspection > Page 4865 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component Information > Testing and Inspection > Page 4869 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component Information > Testing and Inspection > Page 4870 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > Customer Interest for Voltage Regulator: > 841818S > Jul > 85 > Alternator/Regulator Driveability Concerns Voltage Regulator: Customer Interest Alternator/Regulator - Driveability Concerns Article No. 84-18-18-S SURGE, STALL - EEC IV - ALTERNATOR REGULATOR POOR IDLE - EEC IV - ALTERNATOR REGULATOR LOSS OF POWER - EEC IV - ALTERNATOR REGULATOR AM RADIO NOISE - ALTERNATOR REGULATOR FORD 1984 ESCORT, EXP, MUSTANG, LTD, TEMPO, T-BIRD, CROWN VICTORIA LINCOLN-MERCURY 1984 LYNX, CAPRI, MARQUIS, TOPAZ, COUGAR, GRAND MARQUIS, TOWN CAR, MARK VII, CONTINENTAL LIGHT TRUCKS 1984-85 VEHICLES This article is being republished to include Light Truck applications. Some EEC IV vehicles have experienced the subject driveability conditions usually during high ambient temperatures and/or high underhood temperatures. It has also been shown to be an intermittent condition between hot and cold engine compartment temperature. The symptoms may also be induced by repeated engine cranking. The condition may be the result of the voltage regulator causing RF interference to interact with the EEC IV processor. ^ Verify excessively high frequency noise on the low end of the AM radio band. ^ Turn engine OFF. Disconnect the voltage regulator. ^ Start engine. Allow the fuel charging system to stabilize and verify that the subject concerns have been eliminated and the noise on the AM radio band has been significantly diminished. ^ Stop engine. Reconnect the voltage regulator. Restart the engine and verify the return of the symptoms. If the symptoms return, replace the voltage regulator. NOTE: You may have to increase the temperature of the voltage regulator to reproduce the subject symptoms. OTHER APPLICABLE ARTICLES: 84-18-18 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Voltage Regulator: > 841818S > Jul > 85 > Alternator/Regulator - Driveability Concerns Voltage Regulator: All Technical Service Bulletins Alternator/Regulator - Driveability Concerns Article No. 84-18-18-S SURGE, STALL - EEC IV - ALTERNATOR REGULATOR POOR IDLE - EEC IV - ALTERNATOR REGULATOR LOSS OF POWER - EEC IV - ALTERNATOR REGULATOR AM RADIO NOISE - ALTERNATOR REGULATOR FORD 1984 ESCORT, EXP, MUSTANG, LTD, TEMPO, T-BIRD, CROWN VICTORIA LINCOLN-MERCURY 1984 LYNX, CAPRI, MARQUIS, TOPAZ, COUGAR, GRAND MARQUIS, TOWN CAR, MARK VII, CONTINENTAL LIGHT TRUCKS 1984-85 VEHICLES This article is being republished to include Light Truck applications. Some EEC IV vehicles have experienced the subject driveability conditions usually during high ambient temperatures and/or high underhood temperatures. It has also been shown to be an intermittent condition between hot and cold engine compartment temperature. The symptoms may also be induced by repeated engine cranking. The condition may be the result of the voltage regulator causing RF interference to interact with the EEC IV processor. ^ Verify excessively high frequency noise on the low end of the AM radio band. ^ Turn engine OFF. Disconnect the voltage regulator. ^ Start engine. Allow the fuel charging system to stabilize and verify that the subject concerns have been eliminated and the noise on the AM radio band has been significantly diminished. ^ Stop engine. Reconnect the voltage regulator. Restart the engine and verify the return of the symptoms. If the symptoms return, replace the voltage regulator. NOTE: You may have to increase the temperature of the voltage regulator to reproduce the subject symptoms. OTHER APPLICABLE ARTICLES: 84-18-18 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > Page 4884 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > Page 4885 Voltage Regulator: Locations RH Fender Apron w/EEC On RH Fender Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications Ignition Resistor: Specifications BALLAST RESISTOR: Wire Type - Resistance: 1.1 Ohms + or - .05 Ohms Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications > Page 4893 Ignition Resistor: Locations The Ballast Resistor is a wire type and is in-line with the ignition wiring harness located near the steering column. NOTE: Verify vehicle has a ballast resistor by referencing wiring diagram. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions Ignition Lock: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 Ignition Lock: Connector Views For Connector Views, please refer to: Ignition Switch/Diagrams, Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 Ignition Lock: Electrical Diagrams For Wiring Diagrams, please refer to: Starting System/Diagrams, Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) Ignition Lock: Service and Repair Ignition Lock Cylinder Assembly (With Key) Ignition Lock Cylinder Assembly (With Key) Removal 1. Disconnect the battery ground cable. 2. Remove the steering wheel trim pad and the steering wheel for Non-Tilt Steering Columns only. 3. Place the gear shift in PARK (with automatic transmission) and turn the lock cylinder with the ignition key to ON position. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 4903 4. Place 3.17mm (1/8 inch) diameter wire pin or small drift punch and depress the retaining pin while pulling out on the lock cylinder to remove it from the column housing. The pin is located inside the column near.the base of the lock cylinder on Non- Tilt Steering Column. On Tilt-Steering Columns the pin is located adjacent to the Hazard Warning Button. Installation 1. Lubricate the lock cylinder with grease. 2. To install the lock cylinder, turn the lock cylinder to the ON position and depress the retaining pin, then insert the lock cylinder into its housing in the flange casting. Assure that the cylinder is fully seated and aligned into the interlocking washer before turning the key to the OFF position. This action will permit the cylinder retaining pin to extend into the cylinder casting housing hole. 3. Using the ignition key, rotate the lock cylinder to insure correct mechanical operation in all positions. 4. Install the steering wheel and trim pads on Non-Tilt Steering Columns only. 5. Connect the battery ground cable. 6. Check for proper start in Park or Neutral. Also check to make certain that the start circuit cannot be actuated in the Drive and Reverse positions. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 4904 Ignition Lock: Service and Repair Ignition Lock Cylinder Assembly (Without Key) Ignition Lock Cylinder (Without Key) NOTE: The following procedure applies to vehicles where the ignition lock is inoperative and the lock cylinder cannot be rotated due to a lost or broken ignition key and the key number not known or the lock cylinder cap is damaged and/or broken to the extent that the lock cylinder cannot be rotated. Removal 1. Disconnect the battery ground cable. 2. Remove the steering wheel and pad assembly. 3. Remove the turn signal lever from the steering column. 4. To gain access to the ignition switch remove the steering column trim shrouds from the steering column. Detach and lower the steering column assembly from the brake pedal support bracket. 5. Remove the ignition switch and key warning buzzer terminal and pin it in the LOCK position. 6. Remove the turn signal switch from the column assembly. 7. Remove the upper bearing snap ring and the (2) T-bolt retaining nuts that secure the flange casting to the outer tube. Remove the entire flange casting assembly, the upper shaft bearing, the lock cylinder assembly, the ignition switch actuator and the ignition switch actuator rod by pulling the assembly over the end of the steering column shaft. 8. Remove the lock actuator insert, the T-bolts, and the PRND21 insert on automatic transmissions or the key release lever assembly on 4-speed transmissions. 9. Replace the above assembly with a new assembly consisting of: (1) Flange (1) Lock Cylinder Assembly (1) Lock Gear, Steering Column Lock (1) Bearing, Steering Column Lock (1) Retainer, Steering Column Upper Bearing Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 4905 (1) Actuator Assembly, Steering Column Lock 10. Install the key release lever assembly on 4-speed equipped vehicles and the PRND21 insert on vehicles with automatic transmission. Install the T-bolts and lock actuator insert. NOTE: Retain the ignition switch actuating rod from the removed casting assembly and use it with the new flange casting assembly. Installation 1. Reassemble the above parts, install a new upper shaft bearing and set the actuator to drive gear. 2. Install the turn signal-hazard warning switch and key warning buzzer. 3. Install the ignition switch, check and/or adjust for proper function. 4. Install the steering column assembly to the brake pedal support bracket. 5. Install the steering column trim shrouds, steering wheel and pad assembly. 6. Install the turn signal lever. 7. Using the ignition key, rotate the lock cylinder to insure correct mechanical operation in all positions. 8. Connect the battery ground cable. 9. Check for proper start in Park and Neutral. Also check to make certain that the start circuit cannot be actuated in the Drive and Reverse positions. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 4906 Ignition Lock: Service and Repair Ignition Lock Cylinder - Tilt Steering Column Ignition Lock Cylinder-Tilt Steering Column Removal 1. Disconnect the battery ground cable. Remove the steering column trim shrouds. 2. Tape the gap between the steering wheel hub and the cover casting. Cover the entire circumference of the casting. Also cover the adjacent seat and floor area with a suitable covering to protect the surrounding interior upholstery. Pull out the hazard flasher switch and tape it down toward the floor to provide clearance for drilling out the lock cylinder retainer pin. 3. The tilt column lock cylinder retaining pin is located on the outside of the steering column cover casting adjacent to the hazard flasher button. 4. Tilt the steering column to the full up position and prepunch the lock cylinder retaining pin with a prick punch. Using a 3.17mm (1/8 inch) diameter drill with a right angle drive, drill out the retaining pin, going no deeper than 12.7mm (1 /2 inch). NOTE: When drilling out the retaining pin, take care not to damage the cover cast housing or the hazard flasher switch. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 4907 5. Tilt the steering column to the full down position. Place a chisel at the base of the ignition lock cylinder cap, and, using a hammer, strike the chisel with sharp blows to break the cap away from the lock cylinder. 6. Using a 9.8mm (3/8 inch) diameter drill, drill down the middle of the ignition lock key slot approximately 45mm (1-3/4 inch) until the lock cylinder breaks loose from the steering column cover casting. Remove the lock cylinder, and the drill shavings from the base of the cover cast housing. 7. Remove the steering wheel and pad. 8. Remove the turn signal lever from the column and then remove the two attaching screws from the turn signal switch and one attaching screw from the key warning buzzer terminal. Lift the turn signal switch up and over the end of the steering shaft but do not disconnect it from the wiring harness. 9. Remove the four attaching screws from the cover casting and lift the casting over the end of the steering shaft allowing the turn signal switch to pass through the cover casting. The removal of the cover casting will expose the upper actuator. Remove the upper actuator. 10. Remove the drive gear, snap ring and washer from the cover casting along with the upper actuator mentioned above. Thoroughly clean the components in an acceptable cleaning solution. Carefully inspect all components for any damage resulting from the drilling operation. If any of the components show signs of damage, they must be replaced. Clean the removed cover casting with compressed air to remove any drill shavings or foreign particles and carefully inspect it for damage. If the cover casting is damaged, replace it with a new one primed and painted to match the existing column. Installation 1. Lubricate the tang of the lock cylinder with grease. 2. Attach the upper actuator to the lower actuator and lubricate the upper actuator. Reassemble the cover casting, upper actuator, turn signal switch and lever, lock drive gear, lock cylinder, steering wheel and pad, and the steering column trim shrouds. 3. Using the ignition key, rotate the lock cylinder to insure correct mechanical operation in all positions Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 4908 4. Connect the battery ground cable. 5. Check for proper start in Park or Neutral. Also check to make certain that the start circuit cannot be actuated in the Drive and Reverse positions. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 4909 Ignition Lock: Service and Repair Ignition Lock Drive Gear Ignition Lock Drive Gear Removal 1. Remove the lock cylinder assembly. 2. Insert a flat-bladed screwdriver in the recess of the drive gear at the bottom of the lock cylinder housing. Turn the lock drive gear Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Cylinder Assembly (With Key) > Page 4910 counterclockwise three notches. 3. Remove the snap ring, washer and lock drive gear from the lock cylinder housing. Note the position of the drive gear to the rack teeth. Installation 1. Install the lock drive gear in the housing in the same position as noted during removal. Installation is correct if the last tooth on the drive gear is meshed with the last tooth on the rack. Install the washer and snap ring. 2. Using the screwdriver blade, turn the drive gear clockwise three notches. 3. Install the lock cylinder. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 4919 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 4925 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Page 4926 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Location For C6 Transmission Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 4930 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component Information > Testing and Inspection > Armature & Field Grounded Circuit Test > Page 4936 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4941 290000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4942 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4943 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4944 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4945 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4946 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4947 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4948 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4949 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4950 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4951 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4952 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4953 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4954 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4955 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4956 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4957 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4958 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4959 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4960 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 4961 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations On RH front fender Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Component Locations Circuit Breaker: Component Locations LH Side Of Dash Panel At Junction Block Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Component Locations > Page 4970 Circuit Breaker: Fuse and Fusible Link Locations Circuit Location Amps Power Door Locks .................Fuse Panel.....................30 Power Windows.....................In Line At Junction Block......20 Windshield Wiper..................Fuse Panel....................7.5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 4975 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4984 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 4990 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Under LH side of Instrument Panel, to right of parking brake Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4996 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4997 Fig. 1 Fuse Panel. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 5002 Fusible Link: Locations Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 5003 Fusible Link: Locations Fuse Link E At Starter Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 5004 Fusible Link: Locations Fuse Link L Near Auxiliary Blower Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 5005 Fusible Link: Locations Fuse Link B Attached To Auxiliary Battery Relay Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Fuse Link E At Starter Relay Fuse Link L Near Auxiliary Blower Relay Fuse Link Q At Starter Relay Fuse Link R At Starter Relay Fuse Link X At Starter Relay Fuse Links B & D Attached To Auxiliary Battery Relay Or Junction Block Fuse Links C, E, F, K, M & Q At Starter Relay Fuse Links G & H ( W/Ammeter) In Harness, RH Side Of Dash Panel Fuse Links G & R At Starter Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Component Locations Circuit Breaker: Component Locations LH Side Of Dash Panel At Junction Block Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Component Locations > Page 5021 Circuit Breaker: Fuse and Fusible Link Locations Circuit Location Amps Power Door Locks .................Fuse Panel.....................30 Power Windows.....................In Line At Junction Block......20 Windshield Wiper..................Fuse Panel....................7.5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 5026 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5035 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5041 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Under LH side of Instrument Panel, to right of parking brake Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5047 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5048 Fig. 1 Fuse Panel. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 5053 Fusible Link: Locations Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 5054 Fusible Link: Locations Fuse Link E At Starter Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 5055 Fusible Link: Locations Fuse Link L Near Auxiliary Blower Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 5056 Fusible Link: Locations Fuse Link B Attached To Auxiliary Battery Relay Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Fuse Link E At Starter Relay Fuse Link L Near Auxiliary Blower Relay Fuse Link Q At Starter Relay Fuse Link R At Starter Relay Fuse Link X At Starter Relay Fuse Links B & D Attached To Auxiliary Battery Relay Or Junction Block Fuse Links C, E, F, K, M & Q At Starter Relay Fuse Links G & H ( W/Ammeter) In Harness, RH Side Of Dash Panel Fuse Links G & R At Starter Relay Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Alignment: Customer Interest Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull Alignment: Customer Interest Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5080 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5081 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5082 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 5083 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Alignment: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Alignment: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Alignment: All Technical Service Bulletins Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5105 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 (V8-302 5.0L (1985)) 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 5106 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 (V8-302 5.0L (1985)) 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 5107 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 (V8-302 5.0L (1985)) 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 5108 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > NHTSA87V113000 > Jul > 87 > Recall 87V113000: EVAP System Modification Fuel Tank Vent: All Technical Service Bulletins Recall 87V113000: EVAP System Modification EXPULSION OF FUEL DUE TO OVER PRESSURIZATION. FUEL OR FUEL VAPORS IN THE PRESENCE OF AN IGNITION SOURCE CAN CAUSE A FIRE. MODIFICATION OF THE BASE FUEL VENTING AND EMISSION CONTROL SYSTEM TO REDUCE OPERATING TEMPERATURES AND FUEL SYSTEM PRESSURES. SYSTEM: FUEL. VEHICLE DESCRIPTION: AMBULANCE, FORD ECONOLINE E350 CUTAWAY CHASSIS AND VANS,EQUIPPED WITH 7.5 LITER ENGINES. 1983 FORD TRUCK E350 1983 FORD TRUCK ECONOLINE 1984 FORD TRUCK E350 1984 FORD TRUCK ECONOLINE 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE 1987 FORD TRUCK E350 1987 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > NHTSA87V111000 > Jul > 87 > Recall 87V111000: Vapor Valve Grommet Replacement Fuel Tank Vent: All Technical Service Bulletins Recall 87V111000: Vapor Valve Grommet Replacement FUEL LEAK AT THE TOP OF THE FRONT FUEL TANK IN THE AREA OF THE VAPOR VALVE GROMMET. GROMMET MAY SPLIT DUE TO COMPRESSIVE LOAD WHEN INSTALLED IN THE FUEL TANK. FUEL MAY LEAK FROM VAPOR VALVE AND BECOME THE SOURCE OF FUEL FOR A FIRE. INSTALLATION OF A NEWLY DESIGNED VAPOR VALVE GROMMET. SYSTEM: FUEL/TANK VAPOR VALVE. VEHICLE DESCRIPTION: AMBULANCE, ECONOLINE E350 VANS AND CUTAWAY CHASSIS WITH 7.5 LITER ENGINES. 1984 FORD TRUCK E350 1984 FORD TRUCK ECONOLINE 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE 1987 FORD TRUCK E350 1987 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5122 Alignment: By Symptom Technical Service Bulletin # 86622 Date: 860326 Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5123 TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5124 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5125 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5126 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5127 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5128 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5129 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5130 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5131 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5132 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5133 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 # 86622 Date: 860326 Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5134 OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Camber Alignment: Specifications Camber Note: Side to side caster readings must be within 5/8 (degrees), when vehicle riding height is within 1/8 inch side to side. Ride Height 4.25 in -3/4 to + 1/2 deg 4.5 in -1/4 to +1 1/8 deg 4.75 in +3/8 to +1 5/8 deg 5 in +7/8 to +2 1/4 deg 5.25 in +1 3/8 to +2 5/8 deg 5.5 in +1 3/4 to +3 deg 5.75 in +2 1/4 to +3 5/8 deg 6 in +2 3/4 to +4 deg Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Camber > Page 5137 Alignment: Specifications Caster Note: Side to side caster readings must be wintin 1 1/2 (degrees), when vehicle riding height is within 1/8 inch side to side. Ride Height 3.8 in +7 1/2 to +9 1/2 deg 4.05 in +7 to +9 deg 4.3 in +6 1/4 to +8 1/4 deg 4.55 in +5 1/2 to +7 1/2 deg 4.8 in +5 to +7 deg 5.05 in +4 1/2 to +6 1/2 deg 5.3 in +3/4 to +5 3/4 deg 5.55 in +3 3/4 to +5 3/4 deg Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Camber > Page 5138 Alignment: Specifications Toe Toe In .................................................................................................................................................. ........................................................................ 1/32 in Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5139 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5140 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Power Steering Pressure Switch: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement Center Link: Recalls Recall - Supplement II Drag Link Assembly Replacement Number: 86S11 May, 1987 To: Selected North American Ford Product Dealers and Affiliated Ford Motor Companies Subject: Safety Recall 86S11 Supplement II (Steering Drag Link Assembly Replacement) Expansion of Recall to Include Two Additional Days of E250/350 Production Reference: Safety Recall Bulletin 86S11, Dated August, 1986 and Supplemental Bulletin Dated, January, 1987 VEHICLES INVOLVED: 1985 and 1986 E-250/350 Club Wagon and Econoline Vans, Cutaways and Basic Chassis vehicles produced at the Lorain Assembly Plant from March 6, 1985 through May 23, 1986. DESCRIPTION OF THE SUPPLEMENT: The purpose of this supplemental bulletin is to advise you that Recall 86S11 has been expanded to include two additional days of production (May 22, 1986 and May 23, 1986). According to our records, the expanded production dates will affect the vehicles on the enclosed list which have been delivered to your dealership. If no vehicle listing in enclosed, you are not involved at this time, and this Service Recall Bulletin is for information only. NOTIFICATION OF OWNERS/DEALER ACTIONS: The enclosed list identifies vehicles delivered to your dealership which are involved in this recall supplement. Other eligible vehicles may be brought to your dealership by their owners for this recall service. Those units also are to be corrected an promptly as possible. If the owner of any eligible vehicle does not have a Customer Notification and Dealer Claim Form (FED-1864 or FCS-1864), a blank Form 1864 should be completed by you and submitted for reimbursement. For Dealers in Puerto Rico and the Virgin Islands - To determine vehicle eligibility, please use "CARES". Vehicle owners whose names and addresses are shown on the enclosed recall listing are being notified by First Class Mail. If you have knowledge that a suspect vehicle has been sold, but the owner's name and address does not appear on the listing, please contact the owner immediately and provide him a copy of the owner letter. If the owner of any vehicle cannot be contacted or does not make an appointment to have his vehicle corrected, advise your supervising Ford location of the owner's name and address so that we can handle further notification. Owners in Puerto Rico and the U.S. Virgin Islands are being encouraged in the owner letter to ask about any other outstanding recalls on their vehicles when they contact you to arrange an appointment for this recall service. Dealers in those locations can advise them through use of CARES of other recalls, if any, that may be uncompleted. You should attempt to complete all open recalls on these vehicles on a single visit by the owner. DEALER OBLIGATIONS: Dealers are obligated to perform this recall service promptly following presentation of the vehicle by the owners. United States law requires that we advise owners in the Commonwealth of Puerto Rico and certain territories of the procedure to be followed by them in informing the National Highway Traffic Safety Administration, if the defect is not corrected without charge within a reasonable time after the vehicle is brought in. This notice is included in the owner letter (copy attached) to be sent to owners In Puerto Rico, Virgin Islands, American Samoa, Canal Zone, Guam and the Northern Mariana Islands. It is also important, however, that you promptly report (to your supervising location or Wixom) any instances in which an owner will not allow you to complete this recall because of objections to delays in scheduling, or for any other reason. For any suspect vehicle received and already delivered to an owner, it is imperative that you contact the owner immediately, and advise the owner to return the vehicle to your dealership without delay for the inspection/correction. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5156 ECONOLINE - DRAG LINK ASSEMBLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5157 ECONLINE - DRAG LINK ASSEMBLY TECHNICAL INSTRUCTIONS: Refer to Attachment 1. 1. Raise the vehicle on a hoist with the wheels in the straight ahead position. Refer to Section 50-04-1 Hoisting, Jacking and Towing in the 1986 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5158 Truck Pre-Delivery, Lubrication, Maintenance Manual Volume C. 2. Remove the cotter pins and nuts from locations A, B, and C in Attachment I. Remove the ball studs from locations A, B, and C on the drag link assembly using Tool 3290-C, Tie Rod End Remover or an Equivalent as shown in Attachment II. 3. Install the drag link ball stud in the pitman arm. Install the steering connecting arm ball stud in the drag link. Install the drag link ball stud in the spindle. Keep the front wheels and steering wheel in the straight ahead position. Make sure the ball studs are seated in the taper to prevent rotation while tightening. Install nuts and tighten to 68-101 N-m (50-75 ft.lbs). 4. Install new cotter pins. 5. Check toe-in and, if necessary, adjust toe-in as described in Section 14-01-15 General Suspension Service, under adjustments. (See 1986 Truck Shop Manual). PARTS REQUIREMENTS: Do not order recall parts from Windsor Export Supply. Order all requirements directly from Wixom using the mailing address on page No. 1 of this Bulletin. For more urgent handling, use cable address "RECALLS - FORDEX, WIXOM, MICHIGAN". For locations having telex facilities, our telex Ford private line code is FED and commercial telex code is 71 669777 answerback Ford DMO WIX. Our telephone number in Wixom, Michigan, is area code (313) 344-5641. Please give the part number, description, quantity and recall number when ordering. Part Number Description Class Customs Value E6UZ-3304-A Drag Link Assembly RG $56.96 LABOR ALLOWANCES: Installation of the Drag Link Assembly . . . . . . . . . . . . . . . 1.1 Hrs. Insert in Box "B" on Claim Form 1864 (Includes Inspecting, Adjusting Toe and Clear Vision) Administrative Allowance . . . . . . . 0.1 Hrs. The 0.1 Hour Administrative Allowance must be added to the repair time before inserting the total labor time in the correct box. PARTS RETURN: Dealers are requested to purge their current stock of all drag link assemblies as follows: Purge the part number listed below: Service P/N Description D5UZ-3304-B Drag Link Assembly Tag the parts and notify us of the quantity to be purged. We will respond to you with disposition instructions. REPORTING OF COMPLETIONS: Upon completion of the required service, return the second copy of the Form 1864 completely filled out and signed by authorized dealer personnel. Only the Form 1864 will be accepted for reimbursement on this program. It is important that all claims be filed for all completed units so that you will be reimbursed and our records will show completion. Any problem encountered with this recall should be discussed with your supervising Ford location or reported to this office. Dear Owner: This notice is seat to you in accordance with the requirements of the U.S. National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect related to motor vehicle safety exists in certain 1985 and 1986 E-250/350 Econolines and Club Wagons and in specialty vehicles derived from those units. Our records show that you own one or more of these vehicles. REASONS FOR THIS RECALL: The rubber material in a flexible joint that connects the drag link assembly to the pitman arm in the steering linkage of your vehicle may wear out. This could potentially cause the linkage to separate from the steering gear. If this happens, steering control would be lost and a vehicle crash could result. Such a separation would be most likely to occur during a low speed sharp turn, as when parking. If the joint is significantly worn, the driver will be forewarned by: ^ loose or "sloppy" steering feel, as compared to other cars or vans. ^ unusually large amounts of steering wheel free-play, or the need to make unusually large steering wheel movements to accomplish minor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5159 steering changes when traveling on a straight road. SERVICE TO BE PERFORMED: At no cost to you, your dealer will replace the steering drag link assembly of your vehicle. The time to perform this operation is about two hours. WHAT YOU SHOULD DO: Take your vehicle to a Ford dealer without delay. Dealers have instructions for servicing your vehicle. When you bring your vehicle in, please give the attached form to the dealer. If you misplace the form, your dealer will still do the work, free of charge. TO CHECK FOR OTHER RECALLS (Owners residing in Puerto Rico and the U.S. Virgin Islands): When you call your dealer about this recall, ask for a computer check of the "CARES" system to see if your vehicle needs other recall work. If it does, the dealer can tell you about the required service. If you are no longer the owner, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. IF YOU HAVE DIFFICULTIES IN GETTING THE SERVICE DONE: Complete Section 3 of the prepaid postcard and mail it to us. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh St. S. W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 800-424-9393. We regret the inconvenience this service may cause you; but, we want you to have the work done for your safety and satisfaction with your Ford-built vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Recalls: > NHTSA86V094000 > Jul > 86 > Recall 86V094000: Drag Link Replacement Center Link: Recalls Recall 86V094000: Drag Link Replacement THE RUBBER THAT ENCASES BALL STUD AND SOCKET JOINT (CONNECTS STEERING DRAG LINK AND PITMAN ARM) MAY DETERIORATE, CAUSING METAL TO METAL CONTACT, AND MAY EVENTUALLY RESULT IN COMPLETE SEPARATION. CONSEQUENCE OF DEFECT: COMPLETE SEPARATION OF THE DRAG LINK TO PITMAN ARM CONNECTION RESULTS IN LOSS OF STEERING CONTROL WHICH MAY LEAD TO AN ACCIDENT. INSTALL NEW DRAG LINK ASSEMBLIES WITH STEEL BALL AND SOCKET JOINTS AT THE PITMAN ARM CONNECTIONS. SYSTEM: STEERING. VEHICLE DESCRIPTION: E350 ECONOLINE AND CLUB WAGONS. 1985 FORD TRUCK CLUB WAGON 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986 FORD TRUCK CLUB WAGON 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Customer Interest: > 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Customer Interest: > 881414 > Jul > 88 > Steering - Unequal Left and Right Turn Angles > Page 5169 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5175 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement Center Link: All Technical Service Bulletins Recall - Supplement II Drag Link Assembly Replacement Number: 86S11 May, 1987 To: Selected North American Ford Product Dealers and Affiliated Ford Motor Companies Subject: Safety Recall 86S11 Supplement II (Steering Drag Link Assembly Replacement) Expansion of Recall to Include Two Additional Days of E250/350 Production Reference: Safety Recall Bulletin 86S11, Dated August, 1986 and Supplemental Bulletin Dated, January, 1987 VEHICLES INVOLVED: 1985 and 1986 E-250/350 Club Wagon and Econoline Vans, Cutaways and Basic Chassis vehicles produced at the Lorain Assembly Plant from March 6, 1985 through May 23, 1986. DESCRIPTION OF THE SUPPLEMENT: The purpose of this supplemental bulletin is to advise you that Recall 86S11 has been expanded to include two additional days of production (May 22, 1986 and May 23, 1986). According to our records, the expanded production dates will affect the vehicles on the enclosed list which have been delivered to your dealership. If no vehicle listing in enclosed, you are not involved at this time, and this Service Recall Bulletin is for information only. NOTIFICATION OF OWNERS/DEALER ACTIONS: The enclosed list identifies vehicles delivered to your dealership which are involved in this recall supplement. Other eligible vehicles may be brought to your dealership by their owners for this recall service. Those units also are to be corrected an promptly as possible. If the owner of any eligible vehicle does not have a Customer Notification and Dealer Claim Form (FED-1864 or FCS-1864), a blank Form 1864 should be completed by you and submitted for reimbursement. For Dealers in Puerto Rico and the Virgin Islands - To determine vehicle eligibility, please use "CARES". Vehicle owners whose names and addresses are shown on the enclosed recall listing are being notified by First Class Mail. If you have knowledge that a suspect vehicle has been sold, but the owner's name and address does not appear on the listing, please contact the owner immediately and provide him a copy of the owner letter. If the owner of any vehicle cannot be contacted or does not make an appointment to have his vehicle corrected, advise your supervising Ford location of the owner's name and address so that we can handle further notification. Owners in Puerto Rico and the U.S. Virgin Islands are being encouraged in the owner letter to ask about any other outstanding recalls on their vehicles when they contact you to arrange an appointment for this recall service. Dealers in those locations can advise them through use of CARES of other recalls, if any, that may be uncompleted. You should attempt to complete all open recalls on these vehicles on a single visit by the owner. DEALER OBLIGATIONS: Dealers are obligated to perform this recall service promptly following presentation of the vehicle by the owners. United States law requires that we advise owners in the Commonwealth of Puerto Rico and certain territories of the procedure to be followed by them in informing the National Highway Traffic Safety Administration, if the defect is not corrected without charge within a reasonable time after the vehicle is brought in. This notice is included in the owner letter (copy attached) to be sent to owners In Puerto Rico, Virgin Islands, American Samoa, Canal Zone, Guam and the Northern Mariana Islands. It is also important, however, that you promptly report (to your supervising location or Wixom) any instances in which an owner will not allow you to complete this recall because of objections to delays in scheduling, or for any other reason. For any suspect vehicle received and already delivered to an owner, it is imperative that you contact the owner immediately, and advise the owner to return the vehicle to your dealership without delay for the inspection/correction. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5180 ECONOLINE - DRAG LINK ASSEMBLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5181 ECONLINE - DRAG LINK ASSEMBLY TECHNICAL INSTRUCTIONS: Refer to Attachment 1. 1. Raise the vehicle on a hoist with the wheels in the straight ahead position. Refer to Section 50-04-1 Hoisting, Jacking and Towing in the 1986 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5182 Truck Pre-Delivery, Lubrication, Maintenance Manual Volume C. 2. Remove the cotter pins and nuts from locations A, B, and C in Attachment I. Remove the ball studs from locations A, B, and C on the drag link assembly using Tool 3290-C, Tie Rod End Remover or an Equivalent as shown in Attachment II. 3. Install the drag link ball stud in the pitman arm. Install the steering connecting arm ball stud in the drag link. Install the drag link ball stud in the spindle. Keep the front wheels and steering wheel in the straight ahead position. Make sure the ball studs are seated in the taper to prevent rotation while tightening. Install nuts and tighten to 68-101 N-m (50-75 ft.lbs). 4. Install new cotter pins. 5. Check toe-in and, if necessary, adjust toe-in as described in Section 14-01-15 General Suspension Service, under adjustments. (See 1986 Truck Shop Manual). PARTS REQUIREMENTS: Do not order recall parts from Windsor Export Supply. Order all requirements directly from Wixom using the mailing address on page No. 1 of this Bulletin. For more urgent handling, use cable address "RECALLS - FORDEX, WIXOM, MICHIGAN". For locations having telex facilities, our telex Ford private line code is FED and commercial telex code is 71 669777 answerback Ford DMO WIX. Our telephone number in Wixom, Michigan, is area code (313) 344-5641. Please give the part number, description, quantity and recall number when ordering. Part Number Description Class Customs Value E6UZ-3304-A Drag Link Assembly RG $56.96 LABOR ALLOWANCES: Installation of the Drag Link Assembly . . . . . . . . . . . . . . . 1.1 Hrs. Insert in Box "B" on Claim Form 1864 (Includes Inspecting, Adjusting Toe and Clear Vision) Administrative Allowance . . . . . . . 0.1 Hrs. The 0.1 Hour Administrative Allowance must be added to the repair time before inserting the total labor time in the correct box. PARTS RETURN: Dealers are requested to purge their current stock of all drag link assemblies as follows: Purge the part number listed below: Service P/N Description D5UZ-3304-B Drag Link Assembly Tag the parts and notify us of the quantity to be purged. We will respond to you with disposition instructions. REPORTING OF COMPLETIONS: Upon completion of the required service, return the second copy of the Form 1864 completely filled out and signed by authorized dealer personnel. Only the Form 1864 will be accepted for reimbursement on this program. It is important that all claims be filed for all completed units so that you will be reimbursed and our records will show completion. Any problem encountered with this recall should be discussed with your supervising Ford location or reported to this office. Dear Owner: This notice is seat to you in accordance with the requirements of the U.S. National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect related to motor vehicle safety exists in certain 1985 and 1986 E-250/350 Econolines and Club Wagons and in specialty vehicles derived from those units. Our records show that you own one or more of these vehicles. REASONS FOR THIS RECALL: The rubber material in a flexible joint that connects the drag link assembly to the pitman arm in the steering linkage of your vehicle may wear out. This could potentially cause the linkage to separate from the steering gear. If this happens, steering control would be lost and a vehicle crash could result. Such a separation would be most likely to occur during a low speed sharp turn, as when parking. If the joint is significantly worn, the driver will be forewarned by: ^ loose or "sloppy" steering feel, as compared to other cars or vans. ^ unusually large amounts of steering wheel free-play, or the need to make unusually large steering wheel movements to accomplish minor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5183 steering changes when traveling on a straight road. SERVICE TO BE PERFORMED: At no cost to you, your dealer will replace the steering drag link assembly of your vehicle. The time to perform this operation is about two hours. WHAT YOU SHOULD DO: Take your vehicle to a Ford dealer without delay. Dealers have instructions for servicing your vehicle. When you bring your vehicle in, please give the attached form to the dealer. If you misplace the form, your dealer will still do the work, free of charge. TO CHECK FOR OTHER RECALLS (Owners residing in Puerto Rico and the U.S. Virgin Islands): When you call your dealer about this recall, ask for a computer check of the "CARES" system to see if your vehicle needs other recall work. If it does, the dealer can tell you about the required service. If you are no longer the owner, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. IF YOU HAVE DIFFICULTIES IN GETTING THE SERVICE DONE: Complete Section 3 of the prepaid postcard and mail it to us. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh St. S. W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 800-424-9393. We regret the inconvenience this service may cause you; but, we want you to have the work done for your safety and satisfaction with your Ford-built vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > NHTSA86V094000 > Jul > 86 > Recall 86V094000: Drag Link Replacement Center Link: All Technical Service Bulletins Recall 86V094000: Drag Link Replacement THE RUBBER THAT ENCASES BALL STUD AND SOCKET JOINT (CONNECTS STEERING DRAG LINK AND PITMAN ARM) MAY DETERIORATE, CAUSING METAL TO METAL CONTACT, AND MAY EVENTUALLY RESULT IN COMPLETE SEPARATION. CONSEQUENCE OF DEFECT: COMPLETE SEPARATION OF THE DRAG LINK TO PITMAN ARM CONNECTION RESULTS IN LOSS OF STEERING CONTROL WHICH MAY LEAD TO AN ACCIDENT. INSTALL NEW DRAG LINK ASSEMBLIES WITH STEEL BALL AND SOCKET JOINTS AT THE PITMAN ARM CONNECTIONS. SYSTEM: STEERING. VEHICLE DESCRIPTION: E350 ECONOLINE AND CLUB WAGONS. 1985 FORD TRUCK CLUB WAGON 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986 FORD TRUCK CLUB WAGON 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Other 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Link: > 881414 > Jul > 88 > Steering - Unequal Left and Right Turn Angles > Page 5193 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Link: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement Center Link: All Technical Service Bulletins Recall - Supplement II Drag Link Assembly Replacement Number: 86S11 May, 1987 To: Selected North American Ford Product Dealers and Affiliated Ford Motor Companies Subject: Safety Recall 86S11 Supplement II (Steering Drag Link Assembly Replacement) Expansion of Recall to Include Two Additional Days of E250/350 Production Reference: Safety Recall Bulletin 86S11, Dated August, 1986 and Supplemental Bulletin Dated, January, 1987 VEHICLES INVOLVED: 1985 and 1986 E-250/350 Club Wagon and Econoline Vans, Cutaways and Basic Chassis vehicles produced at the Lorain Assembly Plant from March 6, 1985 through May 23, 1986. DESCRIPTION OF THE SUPPLEMENT: The purpose of this supplemental bulletin is to advise you that Recall 86S11 has been expanded to include two additional days of production (May 22, 1986 and May 23, 1986). According to our records, the expanded production dates will affect the vehicles on the enclosed list which have been delivered to your dealership. If no vehicle listing in enclosed, you are not involved at this time, and this Service Recall Bulletin is for information only. NOTIFICATION OF OWNERS/DEALER ACTIONS: The enclosed list identifies vehicles delivered to your dealership which are involved in this recall supplement. Other eligible vehicles may be brought to your dealership by their owners for this recall service. Those units also are to be corrected an promptly as possible. If the owner of any eligible vehicle does not have a Customer Notification and Dealer Claim Form (FED-1864 or FCS-1864), a blank Form 1864 should be completed by you and submitted for reimbursement. For Dealers in Puerto Rico and the Virgin Islands - To determine vehicle eligibility, please use "CARES". Vehicle owners whose names and addresses are shown on the enclosed recall listing are being notified by First Class Mail. If you have knowledge that a suspect vehicle has been sold, but the owner's name and address does not appear on the listing, please contact the owner immediately and provide him a copy of the owner letter. If the owner of any vehicle cannot be contacted or does not make an appointment to have his vehicle corrected, advise your supervising Ford location of the owner's name and address so that we can handle further notification. Owners in Puerto Rico and the U.S. Virgin Islands are being encouraged in the owner letter to ask about any other outstanding recalls on their vehicles when they contact you to arrange an appointment for this recall service. Dealers in those locations can advise them through use of CARES of other recalls, if any, that may be uncompleted. You should attempt to complete all open recalls on these vehicles on a single visit by the owner. DEALER OBLIGATIONS: Dealers are obligated to perform this recall service promptly following presentation of the vehicle by the owners. United States law requires that we advise owners in the Commonwealth of Puerto Rico and certain territories of the procedure to be followed by them in informing the National Highway Traffic Safety Administration, if the defect is not corrected without charge within a reasonable time after the vehicle is brought in. This notice is included in the owner letter (copy attached) to be sent to owners In Puerto Rico, Virgin Islands, American Samoa, Canal Zone, Guam and the Northern Mariana Islands. It is also important, however, that you promptly report (to your supervising location or Wixom) any instances in which an owner will not allow you to complete this recall because of objections to delays in scheduling, or for any other reason. For any suspect vehicle received and already delivered to an owner, it is imperative that you contact the owner immediately, and advise the owner to return the vehicle to your dealership without delay for the inspection/correction. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Link: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5199 ECONOLINE - DRAG LINK ASSEMBLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Link: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5200 ECONLINE - DRAG LINK ASSEMBLY TECHNICAL INSTRUCTIONS: Refer to Attachment 1. 1. Raise the vehicle on a hoist with the wheels in the straight ahead position. Refer to Section 50-04-1 Hoisting, Jacking and Towing in the 1986 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Link: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5201 Truck Pre-Delivery, Lubrication, Maintenance Manual Volume C. 2. Remove the cotter pins and nuts from locations A, B, and C in Attachment I. Remove the ball studs from locations A, B, and C on the drag link assembly using Tool 3290-C, Tie Rod End Remover or an Equivalent as shown in Attachment II. 3. Install the drag link ball stud in the pitman arm. Install the steering connecting arm ball stud in the drag link. Install the drag link ball stud in the spindle. Keep the front wheels and steering wheel in the straight ahead position. Make sure the ball studs are seated in the taper to prevent rotation while tightening. Install nuts and tighten to 68-101 N-m (50-75 ft.lbs). 4. Install new cotter pins. 5. Check toe-in and, if necessary, adjust toe-in as described in Section 14-01-15 General Suspension Service, under adjustments. (See 1986 Truck Shop Manual). PARTS REQUIREMENTS: Do not order recall parts from Windsor Export Supply. Order all requirements directly from Wixom using the mailing address on page No. 1 of this Bulletin. For more urgent handling, use cable address "RECALLS - FORDEX, WIXOM, MICHIGAN". For locations having telex facilities, our telex Ford private line code is FED and commercial telex code is 71 669777 answerback Ford DMO WIX. Our telephone number in Wixom, Michigan, is area code (313) 344-5641. Please give the part number, description, quantity and recall number when ordering. Part Number Description Class Customs Value E6UZ-3304-A Drag Link Assembly RG $56.96 LABOR ALLOWANCES: Installation of the Drag Link Assembly . . . . . . . . . . . . . . . 1.1 Hrs. Insert in Box "B" on Claim Form 1864 (Includes Inspecting, Adjusting Toe and Clear Vision) Administrative Allowance . . . . . . . 0.1 Hrs. The 0.1 Hour Administrative Allowance must be added to the repair time before inserting the total labor time in the correct box. PARTS RETURN: Dealers are requested to purge their current stock of all drag link assemblies as follows: Purge the part number listed below: Service P/N Description D5UZ-3304-B Drag Link Assembly Tag the parts and notify us of the quantity to be purged. We will respond to you with disposition instructions. REPORTING OF COMPLETIONS: Upon completion of the required service, return the second copy of the Form 1864 completely filled out and signed by authorized dealer personnel. Only the Form 1864 will be accepted for reimbursement on this program. It is important that all claims be filed for all completed units so that you will be reimbursed and our records will show completion. Any problem encountered with this recall should be discussed with your supervising Ford location or reported to this office. Dear Owner: This notice is seat to you in accordance with the requirements of the U.S. National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect related to motor vehicle safety exists in certain 1985 and 1986 E-250/350 Econolines and Club Wagons and in specialty vehicles derived from those units. Our records show that you own one or more of these vehicles. REASONS FOR THIS RECALL: The rubber material in a flexible joint that connects the drag link assembly to the pitman arm in the steering linkage of your vehicle may wear out. This could potentially cause the linkage to separate from the steering gear. If this happens, steering control would be lost and a vehicle crash could result. Such a separation would be most likely to occur during a low speed sharp turn, as when parking. If the joint is significantly worn, the driver will be forewarned by: ^ loose or "sloppy" steering feel, as compared to other cars or vans. ^ unusually large amounts of steering wheel free-play, or the need to make unusually large steering wheel movements to accomplish minor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Link: > 86S11 > Jan > 87 > Recall - Supplement II Drag Link Assembly Replacement > Page 5202 steering changes when traveling on a straight road. SERVICE TO BE PERFORMED: At no cost to you, your dealer will replace the steering drag link assembly of your vehicle. The time to perform this operation is about two hours. WHAT YOU SHOULD DO: Take your vehicle to a Ford dealer without delay. Dealers have instructions for servicing your vehicle. When you bring your vehicle in, please give the attached form to the dealer. If you misplace the form, your dealer will still do the work, free of charge. TO CHECK FOR OTHER RECALLS (Owners residing in Puerto Rico and the U.S. Virgin Islands): When you call your dealer about this recall, ask for a computer check of the "CARES" system to see if your vehicle needs other recall work. If it does, the dealer can tell you about the required service. If you are no longer the owner, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. IF YOU HAVE DIFFICULTIES IN GETTING THE SERVICE DONE: Complete Section 3 of the prepaid postcard and mail it to us. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh St. S. W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 800-424-9393. We regret the inconvenience this service may cause you; but, we want you to have the work done for your safety and satisfaction with your Ford-built vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Link: > NHTSA86V094000 > Jul > 86 > Recall 86V094000: Drag Link Replacement Center Link: All Technical Service Bulletins Recall 86V094000: Drag Link Replacement THE RUBBER THAT ENCASES BALL STUD AND SOCKET JOINT (CONNECTS STEERING DRAG LINK AND PITMAN ARM) MAY DETERIORATE, CAUSING METAL TO METAL CONTACT, AND MAY EVENTUALLY RESULT IN COMPLETE SEPARATION. CONSEQUENCE OF DEFECT: COMPLETE SEPARATION OF THE DRAG LINK TO PITMAN ARM CONNECTION RESULTS IN LOSS OF STEERING CONTROL WHICH MAY LEAD TO AN ACCIDENT. INSTALL NEW DRAG LINK ASSEMBLIES WITH STEEL BALL AND SOCKET JOINTS AT THE PITMAN ARM CONNECTIONS. SYSTEM: STEERING. VEHICLE DESCRIPTION: E350 ECONOLINE AND CLUB WAGONS. 1985 FORD TRUCK CLUB WAGON 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986 FORD TRUCK CLUB WAGON 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5218 Power Steering Pump: Service and Repair Disassembly Fig. 1 Exploded view of Ford Model CII power steering pump Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5219 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5220 Power Steering Pump: Service and Repair Assembly Fig. 1 Exploded view of Ford Model CII power steering pump Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5221 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5222 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5223 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5224 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5225 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5226 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5227 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5228 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5229 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5230 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5231 Fig. 2 Removal & installation of return tube, control valve, driveshaft, ball bearing assembly & driveshaft seal Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5232 Fig. 3 Removal & installation of rotating group Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 5233 Fig. 4 Removal & installation of sleeve assembly Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Technical Service Bulletins > Engine Compartment Wiring - Connector Service Power Steering Pressure Switch: Technical Service Bulletins Engine Compartment Wiring Connector Service Article No. 85-17-3 WIRING - ENGINE COMPARTMENT SERVICING TERMINALS/CONNECTORS ON 12A581 AND 14290 ASSEMBLIES FOR INTERMITTENT CONCERNS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCK 1985 ALL When intermittent symptoms are reported and any of the components listed below are suspect, then the following procedure should be performed before the start of normal diagnostics. Component Connectors and Systems Affected: ^ TFI Ignition Module ^ Map Sensor ^ Air Vane Boost Control ^ Power Steering ^ ISC ^ Fuel Injector ^ Anti-Skid Pressure Switch ^ Anti-Skid Control Valve ^ Fluid Level Sensor ^ Main Hydraulic Valve Terminal and Connector Inspection/Repair Procedure 1. Pull on each wire of the subject connector using approximately 3 to 5 lbs. force. 2. If the terminal pulls out of the connector, remove the terminal from wire and replace with a new terminal. 3. Remove wedge from connector and install the new terminal and wire in the connector. 4. Replace the wedge and again pull on the wire. If the new terminal pulls out of connector, replace connector. A. Remove the wedge from connector and remove the remaining terminals, but leave the rubber grommet on wires to aid in reinstalling the terminals in the correct position in the connector. B. Reinstall all terminals into the new connector and reinstall the wedge. C. Install the new connector making sure that it is fully seated to the mating connector (locking fingers completely over ramp). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATON: SP14290B85 TIME: 0.3 Hr. DLR. CODING: Basic Part No. 12A581 and/or 14290 - Code: 44 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service Precautions > Page 5242 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5245 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5246 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5247 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5248 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5249 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5250 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 5251 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Sector Shaft > Component Information > Adjustments Sector Shaft: Adjustments PITMAN SHAFT OVERCENTER PRELOAD 1. Perform steps 1 through 3 of ``Worm Bearing Preload, Adjust'' procedure. 2. Rotate worm shaft from one extreme to the other while counting total number of turns. Turn worm shaft back halfway to center gear. 3. Using inch pound torque wrench, rotate worm shaft approximately 90 degrees across center. Highest reading should be within specifications listed at end of section. Turn sector shaft adjusting screw until proper specification is obtained. 4. Hold sector shaft adjusting screw and tighten locknut to 25 ft. lbs. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Tie Rod End: Customer Interest Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 86622 > Mar > 86 > Steering - Vehicle Drifting/Pulling Tie Rod End: All Technical Service Bulletins Steering - Vehicle Drifting/Pulling Article No. 86-6-22 STEERING - DRIFT/PULL - RUBBER BALL SOCKET LINKAGE WIND-UP LIGHT TRUCK 1985-86 E, F SERIES, BRONCO Complaints of drifts and pulls on certain 1985-86 E, F Series and Bronco models may be caused by the installation procedure of the steering linkage. BECAUSE THE RUBBER TENDS TO RETURN TO ITS INSTALLED POSITION, IT IS IMPERATIVE THAT THE INSTALLATION BE ACCOMPLISHED WITH THE FRONT WHEELS AND THE PITMAN ARM IN THE STRAIGHT AHEAD POSITION, AND THE STUD SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS. Care should be taken with the installation to prevent a drift condition. To diagnose if a preload in the rubber is causing the drift, the following procedure is recommended: 1. Loosen the studs in the tapered holes at the pitman arm and the left and right spindles (i.e., disengage the stud from the hole so that it is no longer seated). 2. Hand install the nuts so that the stud is free to turn inside the tapered hole. 3. INSTALL COTTER PINS IN ALL THE STUDS. 4. Drive the vehicle. If it no longer drifts, then it can be assumed that the rubber was causing the drift. If it continues to drift, the condition is NOT being caused by the rubber ball sockets. 5. In either case, do not replace the steering linkage. Reinstall the linkage as follows: F Series and Bronco 1. Ensure the pitman arm and wheels are in the straight ahead position. (The pitman arm is exactly straight ahead when the clear vision is at 0~.) 2. Lock the steering wheel straight ahead and loose assemble the steering linkage to the pitman arm and then to the spindles. 3. Being careful not to change the position of the pitman arm, torque the steering linkage nuts to 65 ft.lbs. (88.1 N-m) The recommended sequence for tightening is: 1) the pitman arm, 2) the right side spindle and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in if necessary. Econoline 1. Ensure that the wheels are in the straight ahead position. 2. Loose assemble the steering linkage to the spindles and the pitman arm. 3. Being careful not to move the wheels from the straight ahead position, torque the steering linkage nuts to 65 ft.lbs. The recommended tightening sequence is: 1) the right side spindle, 2) the pitman arm and 3) the left side spindle. 4. Install all the cotter pins by advancing the nut to the next castellation. 5. Adjust the toe-in and reset the clear vision if necessary. The above procedure will eliminate any of the drift being caused by the rubber ball sockets. If the vehicle still drifts, refer to Section 19 of the Light Truck Shop Manual for further diagnosis. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3008A86A - F Series and Bronco TIME: 1.4 Hrs. OPERATION: SP3008A86B - Econoline TIME: 1.5 Hrs. DLR. CODING: Basic Part No. 3304 - Code: 36 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information > Service and Repair 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information > Service and Repair > Page 5280 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information > Service and Repair > Page 5281 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Technical Service Bulletins > Page 5289 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear > Page 5297 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 5302 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments > Page 5306 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH Technical Service Bulletin # 88717033088 Date: 880301 Vehicle - Body Boom Between 35 and 65 MPH VIBRATION - DRIVELINE - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE NOISE - "BODY BOOM" - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE Article No. 88-7-17 LIGHT TRUCK: 1983-87 E-150 ISSUE: "Body boom" and driveline vibration between the speeds of 35 and 65 mph (56 and 105 km/h) may be caused by one or more vehicle component areas. The vibration and boom are usually more noticeable when the AOD transmission is operating in overdrive, but may also occur when the AOD transmission is operating in third gear. In most cases there is more than one factor causing the NVH concern. ACTION: To correct this, use the following diagnostic procedures and the 1987 Light Truck Shop Manual, Section 18-01 to determine which vehicle components require attention. The diagnostic procedures should be followed in the order in which they appear in this TSB article. After the completion of each section the vehicle should be road tested to determine if the condition has been corrected. If the condition is still present, proceed to the next section. An Econoline NVH diagnostic chart is on page 52 of this TSB to assist in concern identification. Wheels & Tires, Chassis Groundout & Exhaust System Wheels and Tires 1. Make sure the front wheels are centered on the rotor hub pilot and the rear wheels are centered on the rear drum pilot by using the Rotunda Runout Gauge, 007-00014 to check wheel and tire assembly runout. NOTE: Special attention should be given to vehicles equipped with aftermarket aluminum wheels. 2. If incorrect wheel and tire assembly runout is found, loosen the lug nuts, rotate the wheel and tire assembly and carefully retighten the lug nuts finger tight. 3. Recheck the wheel and tire assembly runout while rotating the wheel and tire assembly. If the runout is okay, torque the lug nuts to 100 ft.lbs. (136 N-m). If runout is still incorrect, service as required. Body to Chassis Groundout 1. Raise the vehicle on a hoist and make sure the mounting bolts from aftermarket seats and safety belt anchors are not grounded to the frame, service as required. 2. Check to make sure the running boards are not grounded to the frame, service as required. 3. Make sure the exhaust system is not grounded to the frame, service as required. Exhaust System 1. Check to make sure an exhaust bind-up condition is not present by using the following steps: a. Road test the vehicle to determine if a "drone" noise is present each time the transmission shifts from one gear to the next between 0 and 65 MPH (0 and 105 km/h). b. If "drone" noise is present, apply the parking brake, depress the brake pedal and brake torque engine to simulate condition. The "drone" should appear around 1800 to 2000 RPM. c. Remove the exhaust system hanger in front and behind the muffler. d. Repeat Step b. If "drone" is gone, loosen the "Y" pipe at the exhaust manifold and the muffler. e. Reposition the exhaust system upward to eliminate stress on the two (2) hangers. Retighten the "Y" pipe to specification. NOTE: On 1987 vehicles, remove the front hanger bracket from the cross member. Knock out the existing retainer bolts from the hanger. Reinstall the bracket with longer bolts and add 1/4" to 1/2" stack of washers to each bolt between the bracket and cross member. This will make sure the rubber isolator is in a neutral position. Driveshaft & Road Test Procedure Information Driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5316 1. Make sure the driveshaft runout does not exceed .035". Refer to the Light Truck Shop Manual, Section 18-01-8. 2. If runout exceeds .035", install a new driveshaft. Refer to the driveshaft application chart on page 49 of this TSB for the correct service part number. 3. Make sure the drive shaft U-joints are not worn. Check for a hard to move U-joint or a U-joint that catches when moved from side to side. NOTE: If it is necessary to replace a U-joint, refer to the following "Road Test" procedure to make sure a driveshaft imbalance is not caused by the U-joint replacement. 4. If the U-joints are okay, mark the driveshaft-to-axle flange with paint to aid in re-indexing. 5. Remove the driveshaft from the axle flange and re-index 180 degrees. 6. Road test the vehicle. NOTE: If the noise and vibration are still present or not acceptable, proceed to the "Road Test" procedure below. Road Test Procedure 1. Select a road where the vehicle can be safely operated at speeds from 25 to 65 MPH (40 to 105 km/h). 2. Slowly accelerate from 25 to 65 MPH (40 to 105 km/h) and observe the speed where the noise and vibration occur. Carefully watch the 35 to 45 MPH (56 to 72 km/h) range. 3. Shift into neutral at 65 MPH (105 km/h) and coast down to 25 MPH (40 km/h) noting at what speed the noise and vibration occur. ^ If the noise and vibration were not present during coast down, the NVH concern is not with an imbalanced driveshaft. ^ Vibrations during a neutral coastdown from 65 to 45 MPH (105 to 72 km/h) indicate an imbalanced driveshaft and/or imbalanced wheel and tire assemblies. ^ Vibrations from 35 to 45 MPH (56 to 72 km/h) indicate an imbalanced driveshaft. ^ Vibration from improperly balanced wheel and tire assemblies are normally FELT in the steering wheel and seats and do not have body "boom" noise associated with it. If this is the case, balance all four (4) wheel and tire assemblies. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5317 ^ An improperly balanced driveshaft will usually have an audible noise or body "boom" noise. If this is the case, balance or replace the driveshaft. Driveshaft Balance & Rear Springs & Axle Information Driveshaft Balance 1. Raise the vehicle on a twin post hoist. 2. Start the engine, engage the transmission and run up to vibration speed. NOTE: Observe the level of vibration in the seat and steering wheel. 3. Have an assistant install one hose clamp at the rear of the driveshaft. Position the clamp with the screw head lined up with the existing balance weights on the driveshaft. 4. Start engine and run up to vibration speed. If the vibration got worse, rotate the clamp 180 degrees. Continue the procedure of rotating at 90 degree increments until all four (4) quadrants have been evaluated. Choose the best position and tighten clamp. 5. If vibration is still present, install a second clamp in the same position as the one installed in Step 4. 6. If vibration increases, scribe a line on the driveshaft at the screwhead locations. 7. Rotate one (1) clamp a 1/2" clockwise and the other 1/2" counterclockwise. Move the clamps further apart or closer together as required to "FINE TUNE" the system. Rear Springs 1. Make sure rear springs are the six leaf design. 2. If not, install two (2) new six leaf springs, (D6UZ-5560-D). Rear Axle 1. If the condition is still present after all the above sections have been completed, road test the vehicle to determine if the correct driveline angle is present or a new ring and pinion assembly is required. 2. Drive vehicle about 10-12 miles (16-19 kilometers). 3. With the transmission in overdrive for AOD transmission or in drive for C6 transmissions, accelerate to 50 MPH (80 km/h). Slowly increase the speed to 65 MPH (105 km/h) noting at what speed the noise and vibration occur. 4. Shift into neutral and coast down to 50 MPH (80 km/h). Observe whether or "boom" noise is present and at what speed. 5. If "boom" is only present in drive, measure the angle between the driveshaft and axle. If greater than 2 degrees, shim the axle at the spring seats to achieve a 1 degree angle. 6. Road test the vehicle. If the "boom" is still present, install a special "low" pitch line runout (PLRO) rear axle ring and pinion set. Refer to the following ring and pinion application chart. RING AND PINION APPLICATION CHART Axle Application Type Ratio Part Number 1983-86 9" 3.50:1 E3UZ-4209-D 1987 8.8" 3.55:1 E7TZ-4209-B NOTE: A new balanced half round circular flange, (E3UZ-4851-A) must be installed in 1983-86 units along with the 9" ring and pinion gear set. NOTE: A "boom" noise during a neutral coast indicates an imbalanced driveline. Refer back to the "Driveshaft Section" for diagnosis. PART NUMBER PART NAME CLASS E6UZ-4602-H Driveshaft C Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5318 E6UZ-4602-J Driveshaft C E6UZ-4602-K Driveshaft C E7UZ-4602-U Driveshaft C E8UZ-4602-C Driveshaft C D6UZ-5560-D Rear Spring C E3UZ-4209-D Ring and Pinion C E7TZ-4209-B Ring and Pinion B E3UZ-4851-A Flange C OTHER APPLICABLE ARTICLES: 86-15-15 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Warranty Coverages OPERATION: 880717A - Wheel and Tire Section (Includes check runout and balance all four wheels and tire assemblies) TIME: 1.6 Hrs. OPERATION: 880717B - Body to Chassis Groundout Section TIME: 0.2 Hr. OPERATION: 880717C - Exhaust System Section TIME: 0.5 Hr. OPERATION: 880717D - Driveshaft and Road Test Sections TIME: 1.1 Hrs. OPERATION: 880717F - Driveshaft Balance Section TIME: 1.4 Hrs. OPERATION: 880717G - Rear Spring Section TIME: 1.4 Hrs. - Both OPERATION: 880717H - Rear Axle Section TIME: 3.5 Hrs. - Standard Axle 4.4 Hrs. - Limited Slip Axle DLR. CODING: Basic Condition Part No.: Code: Wheel and Tire Section 1007 67 Body to Chassis Groundout Section 7000396 35 Exhaust System Section 5260 36 Driveshaft and Road Test Sections 4602 67 Driveshaft Balance Section 4602 67 Rear Spring Section 5560 53 Rear Axle Section 4209 53 NOTE: The only components that are eligible under Powertrain Coverage are part numbers 4209 and 4602. Econoline Nvh Diagnosis Chart Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5319 NOTE: If the complaint unit is a conversion van, be sure to raise vehicle on a hoist and inspect the second seat attachments to verify that the bolts are not too long and grounded to the frame cross member or other components. Also, check running board hangers to make certain that the hangers are not attached to the frame. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application Tires: All Technical Service Bulletins Tires - Best Pressure For Load Application ^33GTIRE - LOAD CAPACITY VERSUS INFLATION PRESSURE ^ TIRE - P - METRIC PASSENGER TIRES USED ON LIGHT TRUCKS ^ TIRE WEAR - EFFECTS OF INFLATION AND LOAD Article No. 89-9-16 LIGHT TRUCK: 1984-89 ALL LIGHT TRUCK LINES ISSUE: Tire wear can be affected by inflation and load. Good tread life is dependent on maintaining proper air pressure in the tires. Other factors that affect tire wear are: ^ alignment ^ speed ^ road surfaces ACTION: Keep tires inflated to the recommended pressures to obtain maximum tread life. Use the following charts and procedures to arrive at the best tire pressure for each load application. FIGURE 1 The chart in Figure 1 shows the affect of inflation and load on tire tread life. Use the chart by finding the specified inflation pressure for the vehicle as shown on the certification label and locating that pressure on the specified inflation pressure on the chart. The affects of actual air pressure and load can now be read directly off the chart. Tire load carrying capacity is a function of tire design and inflation pressures. Each tire has molded into the sidewall a maximum pressure for a specific usage. Use the following guidelines to determine load carrying capacity. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application > Page 5329 FIGURE 2 ^ For P-metric passenger tires on passenger cars, the values are as shown on the tire. ^ For P-metric passenger tires on light trucks, the load ratings are reduced to 91% to reflect the "harsher" truck environment, Figure 2. ^ For light truck style tires used on light trucks, the values are as shown for tires used in single wheel applications. ^ For light truck style tires used in dual wheel applications, the tire capacities are derated. Often, inflation pressures for specific vehicles are less than maximum capacity because the load to be carried is less than the maximum tire capacity. Inflation pressures for originally installed size tires on a vehicle are shown on the vehicle certification label along with the tire size and rated capacity for the axle system. Check the size and inflation information on the label to properly inflate the tires. Be sure that the same size tire is actually on the vehicle and then inflate it to the label's specified pressure. If other than original size tires are on the vehicle, the label's pressures are probably not correct To find proper pressures for other than original tires, use the following procedure. 1. Obtain both front and rear axle capacity ratings (GAWRR and GAWRF). 2. Divide each number by 2 to obtain the capacity at the tire. FIGURE 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application > Page 5330 3. For single wheel usage, look up the pressure in the proper chart which will meet the needed capacity, Figure 3. 4. Check the tire side wall label to see if it permits inflation to that pressure. If lower load range tires were installed (i.e., C vs. D or E), the tires may not have the needed capability. 5. Divide the value found in Step 2 by 2 again to obtain individual tire requirements for dual rear wheels. 6. Using a dual wheel inflation pressure chart, Figure 3, determine correct pressure to achieve adequate load capacities. 7. Consult the local tire outlet or the tire manufacturer's home office about tires not shown in the tables. OTHER APPLICABLE ARTICLES: 87-10-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3300 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH Technical Service Bulletin # 88717033088 Date: 880301 Vehicle - Body Boom Between 35 and 65 MPH VIBRATION - DRIVELINE - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE NOISE - "BODY BOOM" - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE Article No. 88-7-17 LIGHT TRUCK: 1983-87 E-150 ISSUE: "Body boom" and driveline vibration between the speeds of 35 and 65 mph (56 and 105 km/h) may be caused by one or more vehicle component areas. The vibration and boom are usually more noticeable when the AOD transmission is operating in overdrive, but may also occur when the AOD transmission is operating in third gear. In most cases there is more than one factor causing the NVH concern. ACTION: To correct this, use the following diagnostic procedures and the 1987 Light Truck Shop Manual, Section 18-01 to determine which vehicle components require attention. The diagnostic procedures should be followed in the order in which they appear in this TSB article. After the completion of each section the vehicle should be road tested to determine if the condition has been corrected. If the condition is still present, proceed to the next section. An Econoline NVH diagnostic chart is on page 52 of this TSB to assist in concern identification. Wheels & Tires, Chassis Groundout & Exhaust System Wheels and Tires 1. Make sure the front wheels are centered on the rotor hub pilot and the rear wheels are centered on the rear drum pilot by using the Rotunda Runout Gauge, 007-00014 to check wheel and tire assembly runout. NOTE: Special attention should be given to vehicles equipped with aftermarket aluminum wheels. 2. If incorrect wheel and tire assembly runout is found, loosen the lug nuts, rotate the wheel and tire assembly and carefully retighten the lug nuts finger tight. 3. Recheck the wheel and tire assembly runout while rotating the wheel and tire assembly. If the runout is okay, torque the lug nuts to 100 ft.lbs. (136 N-m). If runout is still incorrect, service as required. Body to Chassis Groundout 1. Raise the vehicle on a hoist and make sure the mounting bolts from aftermarket seats and safety belt anchors are not grounded to the frame, service as required. 2. Check to make sure the running boards are not grounded to the frame, service as required. 3. Make sure the exhaust system is not grounded to the frame, service as required. Exhaust System 1. Check to make sure an exhaust bind-up condition is not present by using the following steps: a. Road test the vehicle to determine if a "drone" noise is present each time the transmission shifts from one gear to the next between 0 and 65 MPH (0 and 105 km/h). b. If "drone" noise is present, apply the parking brake, depress the brake pedal and brake torque engine to simulate condition. The "drone" should appear around 1800 to 2000 RPM. c. Remove the exhaust system hanger in front and behind the muffler. d. Repeat Step b. If "drone" is gone, loosen the "Y" pipe at the exhaust manifold and the muffler. e. Reposition the exhaust system upward to eliminate stress on the two (2) hangers. Retighten the "Y" pipe to specification. NOTE: On 1987 vehicles, remove the front hanger bracket from the cross member. Knock out the existing retainer bolts from the hanger. Reinstall the bracket with longer bolts and add 1/4" to 1/2" stack of washers to each bolt between the bracket and cross member. This will make sure the rubber isolator is in a neutral position. Driveshaft & Road Test Procedure Information Driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5335 1. Make sure the driveshaft runout does not exceed .035". Refer to the Light Truck Shop Manual, Section 18-01-8. 2. If runout exceeds .035", install a new driveshaft. Refer to the driveshaft application chart on page 49 of this TSB for the correct service part number. 3. Make sure the drive shaft U-joints are not worn. Check for a hard to move U-joint or a U-joint that catches when moved from side to side. NOTE: If it is necessary to replace a U-joint, refer to the following "Road Test" procedure to make sure a driveshaft imbalance is not caused by the U-joint replacement. 4. If the U-joints are okay, mark the driveshaft-to-axle flange with paint to aid in re-indexing. 5. Remove the driveshaft from the axle flange and re-index 180 degrees. 6. Road test the vehicle. NOTE: If the noise and vibration are still present or not acceptable, proceed to the "Road Test" procedure below. Road Test Procedure 1. Select a road where the vehicle can be safely operated at speeds from 25 to 65 MPH (40 to 105 km/h). 2. Slowly accelerate from 25 to 65 MPH (40 to 105 km/h) and observe the speed where the noise and vibration occur. Carefully watch the 35 to 45 MPH (56 to 72 km/h) range. 3. Shift into neutral at 65 MPH (105 km/h) and coast down to 25 MPH (40 km/h) noting at what speed the noise and vibration occur. ^ If the noise and vibration were not present during coast down, the NVH concern is not with an imbalanced driveshaft. ^ Vibrations during a neutral coastdown from 65 to 45 MPH (105 to 72 km/h) indicate an imbalanced driveshaft and/or imbalanced wheel and tire assemblies. ^ Vibrations from 35 to 45 MPH (56 to 72 km/h) indicate an imbalanced driveshaft. ^ Vibration from improperly balanced wheel and tire assemblies are normally FELT in the steering wheel and seats and do not have body "boom" noise associated with it. If this is the case, balance all four (4) wheel and tire assemblies. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5336 ^ An improperly balanced driveshaft will usually have an audible noise or body "boom" noise. If this is the case, balance or replace the driveshaft. Driveshaft Balance & Rear Springs & Axle Information Driveshaft Balance 1. Raise the vehicle on a twin post hoist. 2. Start the engine, engage the transmission and run up to vibration speed. NOTE: Observe the level of vibration in the seat and steering wheel. 3. Have an assistant install one hose clamp at the rear of the driveshaft. Position the clamp with the screw head lined up with the existing balance weights on the driveshaft. 4. Start engine and run up to vibration speed. If the vibration got worse, rotate the clamp 180 degrees. Continue the procedure of rotating at 90 degree increments until all four (4) quadrants have been evaluated. Choose the best position and tighten clamp. 5. If vibration is still present, install a second clamp in the same position as the one installed in Step 4. 6. If vibration increases, scribe a line on the driveshaft at the screwhead locations. 7. Rotate one (1) clamp a 1/2" clockwise and the other 1/2" counterclockwise. Move the clamps further apart or closer together as required to "FINE TUNE" the system. Rear Springs 1. Make sure rear springs are the six leaf design. 2. If not, install two (2) new six leaf springs, (D6UZ-5560-D). Rear Axle 1. If the condition is still present after all the above sections have been completed, road test the vehicle to determine if the correct driveline angle is present or a new ring and pinion assembly is required. 2. Drive vehicle about 10-12 miles (16-19 kilometers). 3. With the transmission in overdrive for AOD transmission or in drive for C6 transmissions, accelerate to 50 MPH (80 km/h). Slowly increase the speed to 65 MPH (105 km/h) noting at what speed the noise and vibration occur. 4. Shift into neutral and coast down to 50 MPH (80 km/h). Observe whether or "boom" noise is present and at what speed. 5. If "boom" is only present in drive, measure the angle between the driveshaft and axle. If greater than 2 degrees, shim the axle at the spring seats to achieve a 1 degree angle. 6. Road test the vehicle. If the "boom" is still present, install a special "low" pitch line runout (PLRO) rear axle ring and pinion set. Refer to the following ring and pinion application chart. RING AND PINION APPLICATION CHART Axle Application Type Ratio Part Number 1983-86 9" 3.50:1 E3UZ-4209-D 1987 8.8" 3.55:1 E7TZ-4209-B NOTE: A new balanced half round circular flange, (E3UZ-4851-A) must be installed in 1983-86 units along with the 9" ring and pinion gear set. NOTE: A "boom" noise during a neutral coast indicates an imbalanced driveline. Refer back to the "Driveshaft Section" for diagnosis. PART NUMBER PART NAME CLASS E6UZ-4602-H Driveshaft C Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5337 E6UZ-4602-J Driveshaft C E6UZ-4602-K Driveshaft C E7UZ-4602-U Driveshaft C E8UZ-4602-C Driveshaft C D6UZ-5560-D Rear Spring C E3UZ-4209-D Ring and Pinion C E7TZ-4209-B Ring and Pinion B E3UZ-4851-A Flange C OTHER APPLICABLE ARTICLES: 86-15-15 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Warranty Coverages OPERATION: 880717A - Wheel and Tire Section (Includes check runout and balance all four wheels and tire assemblies) TIME: 1.6 Hrs. OPERATION: 880717B - Body to Chassis Groundout Section TIME: 0.2 Hr. OPERATION: 880717C - Exhaust System Section TIME: 0.5 Hr. OPERATION: 880717D - Driveshaft and Road Test Sections TIME: 1.1 Hrs. OPERATION: 880717F - Driveshaft Balance Section TIME: 1.4 Hrs. OPERATION: 880717G - Rear Spring Section TIME: 1.4 Hrs. - Both OPERATION: 880717H - Rear Axle Section TIME: 3.5 Hrs. - Standard Axle 4.4 Hrs. - Limited Slip Axle DLR. CODING: Basic Condition Part No.: Code: Wheel and Tire Section 1007 67 Body to Chassis Groundout Section 7000396 35 Exhaust System Section 5260 36 Driveshaft and Road Test Sections 4602 67 Driveshaft Balance Section 4602 67 Rear Spring Section 5560 53 Rear Axle Section 4209 53 NOTE: The only components that are eligible under Powertrain Coverage are part numbers 4209 and 4602. Econoline Nvh Diagnosis Chart Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5338 NOTE: If the complaint unit is a conversion van, be sure to raise vehicle on a hoist and inspect the second seat attachments to verify that the bolts are not too long and grounded to the frame cross member or other components. Also, check running board hangers to make certain that the hangers are not attached to the frame. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Tires: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Tires: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application Tires: All Technical Service Bulletins Tires - Best Pressure For Load Application ^33GTIRE - LOAD CAPACITY VERSUS INFLATION PRESSURE ^ TIRE - P - METRIC PASSENGER TIRES USED ON LIGHT TRUCKS ^ TIRE WEAR - EFFECTS OF INFLATION AND LOAD Article No. 89-9-16 LIGHT TRUCK: 1984-89 ALL LIGHT TRUCK LINES ISSUE: Tire wear can be affected by inflation and load. Good tread life is dependent on maintaining proper air pressure in the tires. Other factors that affect tire wear are: ^ alignment ^ speed ^ road surfaces ACTION: Keep tires inflated to the recommended pressures to obtain maximum tread life. Use the following charts and procedures to arrive at the best tire pressure for each load application. FIGURE 1 The chart in Figure 1 shows the affect of inflation and load on tire tread life. Use the chart by finding the specified inflation pressure for the vehicle as shown on the certification label and locating that pressure on the specified inflation pressure on the chart. The affects of actual air pressure and load can now be read directly off the chart. Tire load carrying capacity is a function of tire design and inflation pressures. Each tire has molded into the sidewall a maximum pressure for a specific usage. Use the following guidelines to determine load carrying capacity. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application > Page 5356 FIGURE 2 ^ For P-metric passenger tires on passenger cars, the values are as shown on the tire. ^ For P-metric passenger tires on light trucks, the load ratings are reduced to 91% to reflect the "harsher" truck environment, Figure 2. ^ For light truck style tires used on light trucks, the values are as shown for tires used in single wheel applications. ^ For light truck style tires used in dual wheel applications, the tire capacities are derated. Often, inflation pressures for specific vehicles are less than maximum capacity because the load to be carried is less than the maximum tire capacity. Inflation pressures for originally installed size tires on a vehicle are shown on the vehicle certification label along with the tire size and rated capacity for the axle system. Check the size and inflation information on the label to properly inflate the tires. Be sure that the same size tire is actually on the vehicle and then inflate it to the label's specified pressure. If other than original size tires are on the vehicle, the label's pressures are probably not correct To find proper pressures for other than original tires, use the following procedure. 1. Obtain both front and rear axle capacity ratings (GAWRR and GAWRF). 2. Divide each number by 2 to obtain the capacity at the tire. FIGURE 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 89916 > May > 89 > Tires - Best Pressure For Load Application > Page 5357 3. For single wheel usage, look up the pressure in the proper chart which will meet the needed capacity, Figure 3. 4. Check the tire side wall label to see if it permits inflation to that pressure. If lower load range tires were installed (i.e., C vs. D or E), the tires may not have the needed capability. 5. Divide the value found in Step 2 by 2 again to obtain individual tire requirements for dual rear wheels. 6. Using a dual wheel inflation pressure chart, Figure 3, determine correct pressure to achieve adequate load capacities. 7. Consult the local tire outlet or the tire manufacturer's home office about tires not shown in the tables. OTHER APPLICABLE ARTICLES: 87-10-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 3300 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 862427 > Dec > 86 > Front Tires - Irregular Wear Pattern Tires: All Technical Service Bulletins Front Tires - Irregular Wear Pattern Article No. 86-24-27 TIRE WEAR - FRONT - IRREGULAR PATTERN LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire tread/ carcass/compound design. Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and set to Shop Manual preferred settings for toe. In cases of severe wear, obtain the complete alignment readings and tire information. Contact both your Ford Representative and Tire Manufacturer's Representative for their assistance and participation in resolving the customer's concern. Contacting the "local" tire store may not obtain the assistance which may be available from the tire manufacturer. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 862428 > Dec > 86 > Tire Wear - Toe Set Prior Vehicle Service Tires: All Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service Article No. 86-24-28 TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE Certain model vehicles have a significant weight change on the front axle between manufacture by Ford and placement into service. This occurs when incomplete vehicles are completed by a body company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.). This weight change can affect toe setting so these vehicles require that toe be reset. Figure 25 The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes Wheels: Customer Interest Wheel - Mounting Surface Distorted Lug/Pilot Holes Article No. 91-11-16 05/30/91 ^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL WHEELS ^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL WHEELS LIGHT TRUCK: 1985-91 E-250-350, F-250-350 ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a different location. ACTION: To determine if a wheel has been damaged and should not be reused, refer to the following service procedure for details. NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL WHEEL) INSPECT FOR WHEEL DAMAGE 1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel. 2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is distorted, DO NOT reuse the wheel. 3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel. 4. Inspect the wheel mounting surface for distortion. a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which makes contact with the rear brake drum or front rotor). b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt holes and across the center of the pilot hole. c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight edge makes contact with the pilot holes, DO NOT reuse the wheel. INSTALL WHEEL 1. Inspect for lubricants on the studs and lug nuts. 2. If lubricants are present, clean throughly using naphtha or equivalent. 3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual, Section 04-04. CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE TORQUE MAY NOT PROVIDE ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION. PART NUMBER PART NAME CLASS E5TZ-1015-B Wheel AM OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911116A Wheel-Inspect 0.7 hrs 911116B Replace One Wheel And 0.4 Hr. Dynamic Balance 911116C Replace Two Wheels And 0.8 Hr. Dynamic Balance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes > Page 5374 911116D Replace Three Wheels And 1.2 Hr. Dynamic Balance 911116E Replace Four Wheels And 1.6 Hr. Dynamic Balance DEALER CODING BASIC PART NO. CONDITION CODE 1015 67 OASIS CODES: 306000, 703000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH Technical Service Bulletin # 88717033088 Date: 880301 Vehicle - Body Boom Between 35 and 65 MPH VIBRATION - DRIVELINE - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE NOISE - "BODY BOOM" - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE Article No. 88-7-17 LIGHT TRUCK: 1983-87 E-150 ISSUE: "Body boom" and driveline vibration between the speeds of 35 and 65 mph (56 and 105 km/h) may be caused by one or more vehicle component areas. The vibration and boom are usually more noticeable when the AOD transmission is operating in overdrive, but may also occur when the AOD transmission is operating in third gear. In most cases there is more than one factor causing the NVH concern. ACTION: To correct this, use the following diagnostic procedures and the 1987 Light Truck Shop Manual, Section 18-01 to determine which vehicle components require attention. The diagnostic procedures should be followed in the order in which they appear in this TSB article. After the completion of each section the vehicle should be road tested to determine if the condition has been corrected. If the condition is still present, proceed to the next section. An Econoline NVH diagnostic chart is on page 52 of this TSB to assist in concern identification. Wheels & Tires, Chassis Groundout & Exhaust System Wheels and Tires 1. Make sure the front wheels are centered on the rotor hub pilot and the rear wheels are centered on the rear drum pilot by using the Rotunda Runout Gauge, 007-00014 to check wheel and tire assembly runout. NOTE: Special attention should be given to vehicles equipped with aftermarket aluminum wheels. 2. If incorrect wheel and tire assembly runout is found, loosen the lug nuts, rotate the wheel and tire assembly and carefully retighten the lug nuts finger tight. 3. Recheck the wheel and tire assembly runout while rotating the wheel and tire assembly. If the runout is okay, torque the lug nuts to 100 ft.lbs. (136 N-m). If runout is still incorrect, service as required. Body to Chassis Groundout 1. Raise the vehicle on a hoist and make sure the mounting bolts from aftermarket seats and safety belt anchors are not grounded to the frame, service as required. 2. Check to make sure the running boards are not grounded to the frame, service as required. 3. Make sure the exhaust system is not grounded to the frame, service as required. Exhaust System 1. Check to make sure an exhaust bind-up condition is not present by using the following steps: a. Road test the vehicle to determine if a "drone" noise is present each time the transmission shifts from one gear to the next between 0 and 65 MPH (0 and 105 km/h). b. If "drone" noise is present, apply the parking brake, depress the brake pedal and brake torque engine to simulate condition. The "drone" should appear around 1800 to 2000 RPM. c. Remove the exhaust system hanger in front and behind the muffler. d. Repeat Step b. If "drone" is gone, loosen the "Y" pipe at the exhaust manifold and the muffler. e. Reposition the exhaust system upward to eliminate stress on the two (2) hangers. Retighten the "Y" pipe to specification. NOTE: On 1987 vehicles, remove the front hanger bracket from the cross member. Knock out the existing retainer bolts from the hanger. Reinstall the bracket with longer bolts and add 1/4" to 1/2" stack of washers to each bolt between the bracket and cross member. This will make sure the rubber isolator is in a neutral position. Driveshaft & Road Test Procedure Information Driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5379 1. Make sure the driveshaft runout does not exceed .035". Refer to the Light Truck Shop Manual, Section 18-01-8. 2. If runout exceeds .035", install a new driveshaft. Refer to the driveshaft application chart on page 49 of this TSB for the correct service part number. 3. Make sure the drive shaft U-joints are not worn. Check for a hard to move U-joint or a U-joint that catches when moved from side to side. NOTE: If it is necessary to replace a U-joint, refer to the following "Road Test" procedure to make sure a driveshaft imbalance is not caused by the U-joint replacement. 4. If the U-joints are okay, mark the driveshaft-to-axle flange with paint to aid in re-indexing. 5. Remove the driveshaft from the axle flange and re-index 180 degrees. 6. Road test the vehicle. NOTE: If the noise and vibration are still present or not acceptable, proceed to the "Road Test" procedure below. Road Test Procedure 1. Select a road where the vehicle can be safely operated at speeds from 25 to 65 MPH (40 to 105 km/h). 2. Slowly accelerate from 25 to 65 MPH (40 to 105 km/h) and observe the speed where the noise and vibration occur. Carefully watch the 35 to 45 MPH (56 to 72 km/h) range. 3. Shift into neutral at 65 MPH (105 km/h) and coast down to 25 MPH (40 km/h) noting at what speed the noise and vibration occur. ^ If the noise and vibration were not present during coast down, the NVH concern is not with an imbalanced driveshaft. ^ Vibrations during a neutral coastdown from 65 to 45 MPH (105 to 72 km/h) indicate an imbalanced driveshaft and/or imbalanced wheel and tire assemblies. ^ Vibrations from 35 to 45 MPH (56 to 72 km/h) indicate an imbalanced driveshaft. ^ Vibration from improperly balanced wheel and tire assemblies are normally FELT in the steering wheel and seats and do not have body "boom" noise associated with it. If this is the case, balance all four (4) wheel and tire assemblies. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5380 ^ An improperly balanced driveshaft will usually have an audible noise or body "boom" noise. If this is the case, balance or replace the driveshaft. Driveshaft Balance & Rear Springs & Axle Information Driveshaft Balance 1. Raise the vehicle on a twin post hoist. 2. Start the engine, engage the transmission and run up to vibration speed. NOTE: Observe the level of vibration in the seat and steering wheel. 3. Have an assistant install one hose clamp at the rear of the driveshaft. Position the clamp with the screw head lined up with the existing balance weights on the driveshaft. 4. Start engine and run up to vibration speed. If the vibration got worse, rotate the clamp 180 degrees. Continue the procedure of rotating at 90 degree increments until all four (4) quadrants have been evaluated. Choose the best position and tighten clamp. 5. If vibration is still present, install a second clamp in the same position as the one installed in Step 4. 6. If vibration increases, scribe a line on the driveshaft at the screwhead locations. 7. Rotate one (1) clamp a 1/2" clockwise and the other 1/2" counterclockwise. Move the clamps further apart or closer together as required to "FINE TUNE" the system. Rear Springs 1. Make sure rear springs are the six leaf design. 2. If not, install two (2) new six leaf springs, (D6UZ-5560-D). Rear Axle 1. If the condition is still present after all the above sections have been completed, road test the vehicle to determine if the correct driveline angle is present or a new ring and pinion assembly is required. 2. Drive vehicle about 10-12 miles (16-19 kilometers). 3. With the transmission in overdrive for AOD transmission or in drive for C6 transmissions, accelerate to 50 MPH (80 km/h). Slowly increase the speed to 65 MPH (105 km/h) noting at what speed the noise and vibration occur. 4. Shift into neutral and coast down to 50 MPH (80 km/h). Observe whether or "boom" noise is present and at what speed. 5. If "boom" is only present in drive, measure the angle between the driveshaft and axle. If greater than 2 degrees, shim the axle at the spring seats to achieve a 1 degree angle. 6. Road test the vehicle. If the "boom" is still present, install a special "low" pitch line runout (PLRO) rear axle ring and pinion set. Refer to the following ring and pinion application chart. RING AND PINION APPLICATION CHART Axle Application Type Ratio Part Number 1983-86 9" 3.50:1 E3UZ-4209-D 1987 8.8" 3.55:1 E7TZ-4209-B NOTE: A new balanced half round circular flange, (E3UZ-4851-A) must be installed in 1983-86 units along with the 9" ring and pinion gear set. NOTE: A "boom" noise during a neutral coast indicates an imbalanced driveline. Refer back to the "Driveshaft Section" for diagnosis. PART NUMBER PART NAME CLASS E6UZ-4602-H Driveshaft C Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5381 E6UZ-4602-J Driveshaft C E6UZ-4602-K Driveshaft C E7UZ-4602-U Driveshaft C E8UZ-4602-C Driveshaft C D6UZ-5560-D Rear Spring C E3UZ-4209-D Ring and Pinion C E7TZ-4209-B Ring and Pinion B E3UZ-4851-A Flange C OTHER APPLICABLE ARTICLES: 86-15-15 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Warranty Coverages OPERATION: 880717A - Wheel and Tire Section (Includes check runout and balance all four wheels and tire assemblies) TIME: 1.6 Hrs. OPERATION: 880717B - Body to Chassis Groundout Section TIME: 0.2 Hr. OPERATION: 880717C - Exhaust System Section TIME: 0.5 Hr. OPERATION: 880717D - Driveshaft and Road Test Sections TIME: 1.1 Hrs. OPERATION: 880717F - Driveshaft Balance Section TIME: 1.4 Hrs. OPERATION: 880717G - Rear Spring Section TIME: 1.4 Hrs. - Both OPERATION: 880717H - Rear Axle Section TIME: 3.5 Hrs. - Standard Axle 4.4 Hrs. - Limited Slip Axle DLR. CODING: Basic Condition Part No.: Code: Wheel and Tire Section 1007 67 Body to Chassis Groundout Section 7000396 35 Exhaust System Section 5260 36 Driveshaft and Road Test Sections 4602 67 Driveshaft Balance Section 4602 67 Rear Spring Section 5560 53 Rear Axle Section 4209 53 NOTE: The only components that are eligible under Powertrain Coverage are part numbers 4209 and 4602. Econoline Nvh Diagnosis Chart Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5382 NOTE: If the complaint unit is a conversion van, be sure to raise vehicle on a hoist and inspect the second seat attachments to verify that the bolts are not too long and grounded to the frame cross member or other components. Also, check running board hangers to make certain that the hangers are not attached to the frame. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes Wheels: All Technical Service Bulletins Wheel - Mounting Surface Distorted Lug/Pilot Holes Article No. 91-11-16 05/30/91 ^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL WHEELS ^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL WHEELS LIGHT TRUCK: 1985-91 E-250-350, F-250-350 ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a different location. ACTION: To determine if a wheel has been damaged and should not be reused, refer to the following service procedure for details. NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL WHEEL) INSPECT FOR WHEEL DAMAGE 1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel. 2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is distorted, DO NOT reuse the wheel. 3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel. 4. Inspect the wheel mounting surface for distortion. a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which makes contact with the rear brake drum or front rotor). b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt holes and across the center of the pilot hole. c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight edge makes contact with the pilot holes, DO NOT reuse the wheel. INSTALL WHEEL 1. Inspect for lubricants on the studs and lug nuts. 2. If lubricants are present, clean throughly using naphtha or equivalent. 3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual, Section 04-04. CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE TORQUE MAY NOT PROVIDE ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION. PART NUMBER PART NAME CLASS E5TZ-1015-B Wheel AM OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911116A Wheel-Inspect 0.7 hrs 911116B Replace One Wheel And 0.4 Hr. Dynamic Balance 911116C Replace Two Wheels And 0.8 Hr. Dynamic Balance Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes > Page 5388 911116D Replace Three Wheels And 1.2 Hr. Dynamic Balance 911116E Replace Four Wheels And 1.6 Hr. Dynamic Balance DEALER CODING BASIC PART NO. CONDITION CODE 1015 67 OASIS CODES: 306000, 703000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH Technical Service Bulletin # 88717033088 Date: 880301 Vehicle - Body Boom Between 35 and 65 MPH VIBRATION - DRIVELINE - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE NOISE - "BODY BOOM" - 5.0L ENGINE WITH AOD TRANSMISSION OR 5.8L WITH C6 TRANSMISSION - DIAGNOSTIC AND SERVICE PROCEDURE Article No. 88-7-17 LIGHT TRUCK: 1983-87 E-150 ISSUE: "Body boom" and driveline vibration between the speeds of 35 and 65 mph (56 and 105 km/h) may be caused by one or more vehicle component areas. The vibration and boom are usually more noticeable when the AOD transmission is operating in overdrive, but may also occur when the AOD transmission is operating in third gear. In most cases there is more than one factor causing the NVH concern. ACTION: To correct this, use the following diagnostic procedures and the 1987 Light Truck Shop Manual, Section 18-01 to determine which vehicle components require attention. The diagnostic procedures should be followed in the order in which they appear in this TSB article. After the completion of each section the vehicle should be road tested to determine if the condition has been corrected. If the condition is still present, proceed to the next section. An Econoline NVH diagnostic chart is on page 52 of this TSB to assist in concern identification. Wheels & Tires, Chassis Groundout & Exhaust System Wheels and Tires 1. Make sure the front wheels are centered on the rotor hub pilot and the rear wheels are centered on the rear drum pilot by using the Rotunda Runout Gauge, 007-00014 to check wheel and tire assembly runout. NOTE: Special attention should be given to vehicles equipped with aftermarket aluminum wheels. 2. If incorrect wheel and tire assembly runout is found, loosen the lug nuts, rotate the wheel and tire assembly and carefully retighten the lug nuts finger tight. 3. Recheck the wheel and tire assembly runout while rotating the wheel and tire assembly. If the runout is okay, torque the lug nuts to 100 ft.lbs. (136 N-m). If runout is still incorrect, service as required. Body to Chassis Groundout 1. Raise the vehicle on a hoist and make sure the mounting bolts from aftermarket seats and safety belt anchors are not grounded to the frame, service as required. 2. Check to make sure the running boards are not grounded to the frame, service as required. 3. Make sure the exhaust system is not grounded to the frame, service as required. Exhaust System 1. Check to make sure an exhaust bind-up condition is not present by using the following steps: a. Road test the vehicle to determine if a "drone" noise is present each time the transmission shifts from one gear to the next between 0 and 65 MPH (0 and 105 km/h). b. If "drone" noise is present, apply the parking brake, depress the brake pedal and brake torque engine to simulate condition. The "drone" should appear around 1800 to 2000 RPM. c. Remove the exhaust system hanger in front and behind the muffler. d. Repeat Step b. If "drone" is gone, loosen the "Y" pipe at the exhaust manifold and the muffler. e. Reposition the exhaust system upward to eliminate stress on the two (2) hangers. Retighten the "Y" pipe to specification. NOTE: On 1987 vehicles, remove the front hanger bracket from the cross member. Knock out the existing retainer bolts from the hanger. Reinstall the bracket with longer bolts and add 1/4" to 1/2" stack of washers to each bolt between the bracket and cross member. This will make sure the rubber isolator is in a neutral position. Driveshaft & Road Test Procedure Information Driveshaft Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5393 1. Make sure the driveshaft runout does not exceed .035". Refer to the Light Truck Shop Manual, Section 18-01-8. 2. If runout exceeds .035", install a new driveshaft. Refer to the driveshaft application chart on page 49 of this TSB for the correct service part number. 3. Make sure the drive shaft U-joints are not worn. Check for a hard to move U-joint or a U-joint that catches when moved from side to side. NOTE: If it is necessary to replace a U-joint, refer to the following "Road Test" procedure to make sure a driveshaft imbalance is not caused by the U-joint replacement. 4. If the U-joints are okay, mark the driveshaft-to-axle flange with paint to aid in re-indexing. 5. Remove the driveshaft from the axle flange and re-index 180 degrees. 6. Road test the vehicle. NOTE: If the noise and vibration are still present or not acceptable, proceed to the "Road Test" procedure below. Road Test Procedure 1. Select a road where the vehicle can be safely operated at speeds from 25 to 65 MPH (40 to 105 km/h). 2. Slowly accelerate from 25 to 65 MPH (40 to 105 km/h) and observe the speed where the noise and vibration occur. Carefully watch the 35 to 45 MPH (56 to 72 km/h) range. 3. Shift into neutral at 65 MPH (105 km/h) and coast down to 25 MPH (40 km/h) noting at what speed the noise and vibration occur. ^ If the noise and vibration were not present during coast down, the NVH concern is not with an imbalanced driveshaft. ^ Vibrations during a neutral coastdown from 65 to 45 MPH (105 to 72 km/h) indicate an imbalanced driveshaft and/or imbalanced wheel and tire assemblies. ^ Vibrations from 35 to 45 MPH (56 to 72 km/h) indicate an imbalanced driveshaft. ^ Vibration from improperly balanced wheel and tire assemblies are normally FELT in the steering wheel and seats and do not have body "boom" noise associated with it. If this is the case, balance all four (4) wheel and tire assemblies. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5394 ^ An improperly balanced driveshaft will usually have an audible noise or body "boom" noise. If this is the case, balance or replace the driveshaft. Driveshaft Balance & Rear Springs & Axle Information Driveshaft Balance 1. Raise the vehicle on a twin post hoist. 2. Start the engine, engage the transmission and run up to vibration speed. NOTE: Observe the level of vibration in the seat and steering wheel. 3. Have an assistant install one hose clamp at the rear of the driveshaft. Position the clamp with the screw head lined up with the existing balance weights on the driveshaft. 4. Start engine and run up to vibration speed. If the vibration got worse, rotate the clamp 180 degrees. Continue the procedure of rotating at 90 degree increments until all four (4) quadrants have been evaluated. Choose the best position and tighten clamp. 5. If vibration is still present, install a second clamp in the same position as the one installed in Step 4. 6. If vibration increases, scribe a line on the driveshaft at the screwhead locations. 7. Rotate one (1) clamp a 1/2" clockwise and the other 1/2" counterclockwise. Move the clamps further apart or closer together as required to "FINE TUNE" the system. Rear Springs 1. Make sure rear springs are the six leaf design. 2. If not, install two (2) new six leaf springs, (D6UZ-5560-D). Rear Axle 1. If the condition is still present after all the above sections have been completed, road test the vehicle to determine if the correct driveline angle is present or a new ring and pinion assembly is required. 2. Drive vehicle about 10-12 miles (16-19 kilometers). 3. With the transmission in overdrive for AOD transmission or in drive for C6 transmissions, accelerate to 50 MPH (80 km/h). Slowly increase the speed to 65 MPH (105 km/h) noting at what speed the noise and vibration occur. 4. Shift into neutral and coast down to 50 MPH (80 km/h). Observe whether or "boom" noise is present and at what speed. 5. If "boom" is only present in drive, measure the angle between the driveshaft and axle. If greater than 2 degrees, shim the axle at the spring seats to achieve a 1 degree angle. 6. Road test the vehicle. If the "boom" is still present, install a special "low" pitch line runout (PLRO) rear axle ring and pinion set. Refer to the following ring and pinion application chart. RING AND PINION APPLICATION CHART Axle Application Type Ratio Part Number 1983-86 9" 3.50:1 E3UZ-4209-D 1987 8.8" 3.55:1 E7TZ-4209-B NOTE: A new balanced half round circular flange, (E3UZ-4851-A) must be installed in 1983-86 units along with the 9" ring and pinion gear set. NOTE: A "boom" noise during a neutral coast indicates an imbalanced driveline. Refer back to the "Driveshaft Section" for diagnosis. PART NUMBER PART NAME CLASS E6UZ-4602-H Driveshaft C Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5395 E6UZ-4602-J Driveshaft C E6UZ-4602-K Driveshaft C E7UZ-4602-U Driveshaft C E8UZ-4602-C Driveshaft C D6UZ-5560-D Rear Spring C E3UZ-4209-D Ring and Pinion C E7TZ-4209-B Ring and Pinion B E3UZ-4851-A Flange C OTHER APPLICABLE ARTICLES: 86-15-15 WARRANTY STATUS: Eligible Under Basic Warranty and Powertrain Warranty Coverages OPERATION: 880717A - Wheel and Tire Section (Includes check runout and balance all four wheels and tire assemblies) TIME: 1.6 Hrs. OPERATION: 880717B - Body to Chassis Groundout Section TIME: 0.2 Hr. OPERATION: 880717C - Exhaust System Section TIME: 0.5 Hr. OPERATION: 880717D - Driveshaft and Road Test Sections TIME: 1.1 Hrs. OPERATION: 880717F - Driveshaft Balance Section TIME: 1.4 Hrs. OPERATION: 880717G - Rear Spring Section TIME: 1.4 Hrs. - Both OPERATION: 880717H - Rear Axle Section TIME: 3.5 Hrs. - Standard Axle 4.4 Hrs. - Limited Slip Axle DLR. CODING: Basic Condition Part No.: Code: Wheel and Tire Section 1007 67 Body to Chassis Groundout Section 7000396 35 Exhaust System Section 5260 36 Driveshaft and Road Test Sections 4602 67 Driveshaft Balance Section 4602 67 Rear Spring Section 5560 53 Rear Axle Section 4209 53 NOTE: The only components that are eligible under Powertrain Coverage are part numbers 4209 and 4602. Econoline Nvh Diagnosis Chart Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 88717033088 > Mar > 88 > Vehicle - Body Boom Between 35 and 65 MPH > Page 5396 NOTE: If the complaint unit is a conversion van, be sure to raise vehicle on a hoist and inspect the second seat attachments to verify that the bolts are not too long and grounded to the frame cross member or other components. Also, check running board hangers to make certain that the hangers are not attached to the frame. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update Wheels: All Technical Service Bulletins Wheel Attachment - Shop Manual Update Article No. 85-15-9 WHEEL ATTACHMENT - 1985 SHOP MANUAL UPDATE LIGHT TRUCK 1985 E350, F350 The following information, outlined in Section 50-2, but not shown or outlined in Section 50-11, should be added to the 1985 Light Truck Shop Manual-Section 50-11 as indicated below: Figure 3 - LIGHT TRUCK F/E/BRONCO Figure 4 - REAR WHEEL LUG NUT USAGE 1. On Page 50-11-7: Add Figure 3 of the attached sketches to Figure l0 of Page 5O-11-7 - Lug Nut Tightening Sequence. This figure shows the lug nut tightening sequence for the 5-lug and 8-lug wheels used on all light truck models and indicates the recommended lug nut tightening procedure. Figure 4 of the attached sketches shows the two wheel lug nut designs released for 1985 Light Truck vehicles. Figure 4 - REAR WHEEL LUG NUT USAGE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 5401 Figure 5 - REAR WHEEL INSTALLATION - F-350 / E-350 EQUIPPED WITH DUAL REAR WHEELS 2. On Page 50-11-7: The note concerning E350 and F350 vehicles equipped with dual rear wheels should be deleted and the following note and Figures 4 and 5 of the attached sketches be added: E350 and F350 vehicles with dual rear wheels are equipped with wheels (front/rear) which are center piloted to the hub and are attached with integral two-piece, swiveling lug nuts. The lug nut torque specification is 140 ft.lbs. +/- 15 ft.lbs. (right hand threads are used at all four wheel locations). See Figure 5 of the attached sketches for description of the wheel attachments. Figure 4 - REAR WHEEL LUG NUT USAGE WARNING: Use only integral two-piece swiveling lug nuts on 1985 vehicles equipped with dual rear wheels. Do not attempt to use cone shaped onepiece lug nuts on these vehicles. If used on wrong wheels, cone shaped one-piece lug nuts can come loose in vehicle operation. Do not attempt to use wheels which have cone shaped lug nut seats on these vehicles. Intermixing of different types of wheels can lead to damage to the wheel mounting system. Use of cone shaped one-piece nuts or intermixing of wheels could allow wheels to come off while vehicle is in motion, possibly causing loss of control and a collision. See Figure 4 of the attached sketch for lug nut description." 3. On Page 50-11-8: Delete the wheel "Torque Limits" chart and add the "Wheel Torque Limits" chart as shown. REFERENCE: For pre-delivery and wheel maintenance, refer to Pages 50-02-4, 5, 6, 7 and 51 in the 1985 Light Truck Shop Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 5402 Figure 6 - MODEL E350-F350 DUAL REAR WHEEL STUD NUTS USAGE INFORMATION For a complete description of the new and prior model dual rear wheel mounting systems for model E350 and F350 vehicles equipped with dual rear wheels, refer to the attached Figure 6. Torque Limits* Description - Model Bolt Size (Ft. Lbs.) N-m F-150, E-150, and Bronco-5-Lug Wheel 1/2-20 (85-115) 115-156 F-250 - E-350, E-250 - E-350, 8-Lug Wheel (under 8,500 GVW) 1/2-20 (85-115) 115-156 F-250 - F-350, E-250 - E-350, 8-Lug Wheel (over 8,500 GVW, Single Rear Wheel Vehicles) 9/16-18 (115-175) 156-237 F-350 - E-350, 8-Lug Wheel - Front or Rear (Dual Rear Wheel Vehicles with Integral Two-Piece Swiveling Lug Nuts) 9-16-18 (125-155) 169-210 *Torque specifications are for dirt and paint free dry bolt and nut threads. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update Wheels: All Technical Service Bulletins Wheel Attachment - Shop Manual Update Article No. 85-15-9 WHEEL ATTACHMENT - 1985 SHOP MANUAL UPDATE LIGHT TRUCK 1985 E350, F350 The following information, outlined in Section 50-2, but not shown or outlined in Section 50-11, should be added to the 1985 Light Truck Shop Manual-Section 50-11 as indicated below: Figure 3 - LIGHT TRUCK F/E/BRONCO Figure 4 - REAR WHEEL LUG NUT USAGE 1. On Page 50-11-7: Add Figure 3 of the attached sketches to Figure l0 of Page 5O-11-7 - Lug Nut Tightening Sequence. This figure shows the lug nut tightening sequence for the 5-lug and 8-lug wheels used on all light truck models and indicates the recommended lug nut tightening procedure. Figure 4 of the attached sketches shows the two wheel lug nut designs released for 1985 Light Truck vehicles. Figure 4 - REAR WHEEL LUG NUT USAGE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 5408 Figure 5 - REAR WHEEL INSTALLATION - F-350 / E-350 EQUIPPED WITH DUAL REAR WHEELS 2. On Page 50-11-7: The note concerning E350 and F350 vehicles equipped with dual rear wheels should be deleted and the following note and Figures 4 and 5 of the attached sketches be added: E350 and F350 vehicles with dual rear wheels are equipped with wheels (front/rear) which are center piloted to the hub and are attached with integral two-piece, swiveling lug nuts. The lug nut torque specification is 140 ft.lbs. +/- 15 ft.lbs. (right hand threads are used at all four wheel locations). See Figure 5 of the attached sketches for description of the wheel attachments. Figure 4 - REAR WHEEL LUG NUT USAGE WARNING: Use only integral two-piece swiveling lug nuts on 1985 vehicles equipped with dual rear wheels. Do not attempt to use cone shaped onepiece lug nuts on these vehicles. If used on wrong wheels, cone shaped one-piece lug nuts can come loose in vehicle operation. Do not attempt to use wheels which have cone shaped lug nut seats on these vehicles. Intermixing of different types of wheels can lead to damage to the wheel mounting system. Use of cone shaped one-piece nuts or intermixing of wheels could allow wheels to come off while vehicle is in motion, possibly causing loss of control and a collision. See Figure 4 of the attached sketch for lug nut description." 3. On Page 50-11-8: Delete the wheel "Torque Limits" chart and add the "Wheel Torque Limits" chart as shown. REFERENCE: For pre-delivery and wheel maintenance, refer to Pages 50-02-4, 5, 6, 7 and 51 in the 1985 Light Truck Shop Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 5409 Figure 6 - MODEL E350-F350 DUAL REAR WHEEL STUD NUTS USAGE INFORMATION For a complete description of the new and prior model dual rear wheel mounting systems for model E350 and F350 vehicles equipped with dual rear wheels, refer to the attached Figure 6. Torque Limits* Description - Model Bolt Size (Ft. Lbs.) N-m F-150, E-150, and Bronco-5-Lug Wheel 1/2-20 (85-115) 115-156 F-250 - E-350, E-250 - E-350, 8-Lug Wheel (under 8,500 GVW) 1/2-20 (85-115) 115-156 F-250 - F-350, E-250 - E-350, 8-Lug Wheel (over 8,500 GVW, Single Rear Wheel Vehicles) 9/16-18 (115-175) 156-237 F-350 - E-350, 8-Lug Wheel - Front or Rear (Dual Rear Wheel Vehicles with Integral Two-Piece Swiveling Lug Nuts) 9-16-18 (125-155) 169-210 *Torque specifications are for dirt and paint free dry bolt and nut threads. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments > Page 5413 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On Studs Wheel Fastener: Customer Interest Wheels- Lug Nuts Bind On Studs Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES 87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS LIGHT TRUCK: 1983-87 E-250/350, F-250/350 ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped in" against the stud when torqued. ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the recommended torque of 140 ft.lbs. (190 N-m). CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at intervals specified in the Owner Guide. PART NUMBER PART NAME CLASS E7TZ-1120-A Lug Nut - R.H. Thread A - Package of 4 E7TZ-1121-A Lug Nut - L.H. Thread A - Package of 4 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME: 0.5 Hr. OPERATION: 1107B - Replace wheel studs TIME: Refer to the appropriate Service Labor Time Standards Manual OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District Authorization DLR. CODING: Basic Part No. 1120 - Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 5427 ^ 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 5428 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On Studs Wheel Fastener: All Technical Service Bulletins Wheels- Lug Nuts Bind On Studs Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES 87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS LIGHT TRUCK: 1983-87 E-250/350, F-250/350 ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped in" against the stud when torqued. ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the recommended torque of 140 ft.lbs. (190 N-m). CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at intervals specified in the Owner Guide. PART NUMBER PART NAME CLASS E7TZ-1120-A Lug Nut - R.H. Thread A - Package of 4 E7TZ-1121-A Lug Nut - L.H. Thread A - Package of 4 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME: 0.5 Hr. OPERATION: 1107B - Replace wheel studs TIME: Refer to the appropriate Service Labor Time Standards Manual OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District Authorization DLR. CODING: Basic Part No. 1120 - Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment Shop Manual Update Wheel Fastener: All Technical Service Bulletins Wheel Attachment - Shop Manual Update Article No. 85-15-9 WHEEL ATTACHMENT - 1985 SHOP MANUAL UPDATE LIGHT TRUCK 1985 E350, F350 The following information, outlined in Section 50-2, but not shown or outlined in Section 50-11, should be added to the 1985 Light Truck Shop Manual-Section 50-11 as indicated below: Figure 3 - LIGHT TRUCK F/E/BRONCO Figure 4 - REAR WHEEL LUG NUT USAGE 1. On Page 50-11-7: Add Figure 3 of the attached sketches to Figure l0 of Page 5O-11-7 - Lug Nut Tightening Sequence. This figure shows the lug nut tightening sequence for the 5-lug and 8-lug wheels used on all light truck models and indicates the recommended lug nut tightening procedure. Figure 4 of the attached sketches shows the two wheel lug nut designs released for 1985 Light Truck vehicles. Figure 4 - REAR WHEEL LUG NUT USAGE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment Shop Manual Update > Page 5437 Figure 5 - REAR WHEEL INSTALLATION - F-350 / E-350 EQUIPPED WITH DUAL REAR WHEELS 2. On Page 50-11-7: The note concerning E350 and F350 vehicles equipped with dual rear wheels should be deleted and the following note and Figures 4 and 5 of the attached sketches be added: E350 and F350 vehicles with dual rear wheels are equipped with wheels (front/rear) which are center piloted to the hub and are attached with integral two-piece, swiveling lug nuts. The lug nut torque specification is 140 ft.lbs. +/- 15 ft.lbs. (right hand threads are used at all four wheel locations). See Figure 5 of the attached sketches for description of the wheel attachments. Figure 4 - REAR WHEEL LUG NUT USAGE WARNING: Use only integral two-piece swiveling lug nuts on 1985 vehicles equipped with dual rear wheels. Do not attempt to use cone shaped onepiece lug nuts on these vehicles. If used on wrong wheels, cone shaped one-piece lug nuts can come loose in vehicle operation. Do not attempt to use wheels which have cone shaped lug nut seats on these vehicles. Intermixing of different types of wheels can lead to damage to the wheel mounting system. Use of cone shaped one-piece nuts or intermixing of wheels could allow wheels to come off while vehicle is in motion, possibly causing loss of control and a collision. See Figure 4 of the attached sketch for lug nut description." 3. On Page 50-11-8: Delete the wheel "Torque Limits" chart and add the "Wheel Torque Limits" chart as shown. REFERENCE: For pre-delivery and wheel maintenance, refer to Pages 50-02-4, 5, 6, 7 and 51 in the 1985 Light Truck Shop Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment Shop Manual Update > Page 5438 Figure 6 - MODEL E350-F350 DUAL REAR WHEEL STUD NUTS USAGE INFORMATION For a complete description of the new and prior model dual rear wheel mounting systems for model E350 and F350 vehicles equipped with dual rear wheels, refer to the attached Figure 6. Torque Limits* Description - Model Bolt Size (Ft. Lbs.) N-m F-150, E-150, and Bronco-5-Lug Wheel 1/2-20 (85-115) 115-156 F-250 - E-350, E-250 - E-350, 8-Lug Wheel (under 8,500 GVW) 1/2-20 (85-115) 115-156 F-250 - F-350, E-250 - E-350, 8-Lug Wheel (over 8,500 GVW, Single Rear Wheel Vehicles) 9/16-18 (115-175) 156-237 F-350 - E-350, 8-Lug Wheel - Front or Rear (Dual Rear Wheel Vehicles with Integral Two-Piece Swiveling Lug Nuts) 9-16-18 (125-155) 169-210 *Torque specifications are for dirt and paint free dry bolt and nut threads. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 5444 ^ 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 5445 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update Wheel Fastener: All Technical Service Bulletins Wheel Attachment - Shop Manual Update Article No. 85-15-9 WHEEL ATTACHMENT - 1985 SHOP MANUAL UPDATE LIGHT TRUCK 1985 E350, F350 The following information, outlined in Section 50-2, but not shown or outlined in Section 50-11, should be added to the 1985 Light Truck Shop Manual-Section 50-11 as indicated below: Figure 3 - LIGHT TRUCK F/E/BRONCO Figure 4 - REAR WHEEL LUG NUT USAGE 1. On Page 50-11-7: Add Figure 3 of the attached sketches to Figure l0 of Page 5O-11-7 - Lug Nut Tightening Sequence. This figure shows the lug nut tightening sequence for the 5-lug and 8-lug wheels used on all light truck models and indicates the recommended lug nut tightening procedure. Figure 4 of the attached sketches shows the two wheel lug nut designs released for 1985 Light Truck vehicles. Figure 4 - REAR WHEEL LUG NUT USAGE Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 5450 Figure 5 - REAR WHEEL INSTALLATION - F-350 / E-350 EQUIPPED WITH DUAL REAR WHEELS 2. On Page 50-11-7: The note concerning E350 and F350 vehicles equipped with dual rear wheels should be deleted and the following note and Figures 4 and 5 of the attached sketches be added: E350 and F350 vehicles with dual rear wheels are equipped with wheels (front/rear) which are center piloted to the hub and are attached with integral two-piece, swiveling lug nuts. The lug nut torque specification is 140 ft.lbs. +/- 15 ft.lbs. (right hand threads are used at all four wheel locations). See Figure 5 of the attached sketches for description of the wheel attachments. Figure 4 - REAR WHEEL LUG NUT USAGE WARNING: Use only integral two-piece swiveling lug nuts on 1985 vehicles equipped with dual rear wheels. Do not attempt to use cone shaped onepiece lug nuts on these vehicles. If used on wrong wheels, cone shaped one-piece lug nuts can come loose in vehicle operation. Do not attempt to use wheels which have cone shaped lug nut seats on these vehicles. Intermixing of different types of wheels can lead to damage to the wheel mounting system. Use of cone shaped one-piece nuts or intermixing of wheels could allow wheels to come off while vehicle is in motion, possibly causing loss of control and a collision. See Figure 4 of the attached sketch for lug nut description." 3. On Page 50-11-8: Delete the wheel "Torque Limits" chart and add the "Wheel Torque Limits" chart as shown. REFERENCE: For pre-delivery and wheel maintenance, refer to Pages 50-02-4, 5, 6, 7 and 51 in the 1985 Light Truck Shop Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 85159 > Jul > 85 > Wheel Attachment - Shop Manual Update > Page 5451 Figure 6 - MODEL E350-F350 DUAL REAR WHEEL STUD NUTS USAGE INFORMATION For a complete description of the new and prior model dual rear wheel mounting systems for model E350 and F350 vehicles equipped with dual rear wheels, refer to the attached Figure 6. Torque Limits* Description - Model Bolt Size (Ft. Lbs.) N-m F-150, E-150, and Bronco-5-Lug Wheel 1/2-20 (85-115) 115-156 F-250 - E-350, E-250 - E-350, 8-Lug Wheel (under 8,500 GVW) 1/2-20 (85-115) 115-156 F-250 - F-350, E-250 - E-350, 8-Lug Wheel (over 8,500 GVW, Single Rear Wheel Vehicles) 9/16-18 (115-175) 156-237 F-350 - E-350, 8-Lug Wheel - Front or Rear (Dual Rear Wheel Vehicles with Integral Two-Piece Swiveling Lug Nuts) 9-16-18 (125-155) 169-210 *Torque specifications are for dirt and paint free dry bolt and nut threads. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Lug Nut Torque Patterns IMPORTANT Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for rust, damage, or dirt. Clean mating surfaces with a wire brush to remove any foreign material. Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a major cause of tire installation problems. Proper installation, including fastener torque, is essential to economical, safe and trouble free service. Use only the proper sizes and types of fasteners for safe and proper service. Tighten the fasteners a quarter turn at a time using the tightening sequence diagram as a guide. This is very important to prevent misalignment of the wheel. Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque (See WHEEL FASTENER TORQUE). CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or alignment problems. After driving the vehicle for a short distance, recheck the wheel fastener torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all fasteners to the proper torque. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 5454 Wheel Fastener: Specifications Wheel Tightening Torque 1991-92 Explorer.................................................................................................................................. .................................................................100 ft/lbs 1987-92 E150....................................................................................................................................... ..................................................................100 ft/lbs 1987-92 F150....................................................................................................................................... ..................................................................100 ft/lbs 1987-92 Bronco.................................................................................................................................... ..................................................................100 ft/lbs 1987-92 Bronco II................................................................................................................................. .................................................................100 ft/lbs 1987-92 Aerostar.................................................................................................................................. ..................................................................100 ft/lbs 1987-92 Ranger.................................................................................................................................... ..................................................................100 ft/lbs 1987-92 E250....................................................................................................................................... ..................................................................140 ft/lbs 1987-92 E350....................................................................................................................................... ..................................................................140 ft/lbs 1987-92 F250....................................................................................................................................... ..................................................................140 ft/lbs 1987-92 F350....................................................................................................................................... ..................................................................140 ft/lbs 1985-86 E150....................................................................................................................................... .............................................................85-115 ft/lbs 1985-86 E200....................................................................................................................................... .............................................................85-115 ft/lbs 1985-86 F150....................................................................................................................................... .............................................................85-115 ft/lbs 1985-86 F200....................................................................................................................................... .............................................................85-115 ft/lbs 1985-86 Bronco.................................................................................................................................... ............................................................85-115 ft/lbs 1985-86 E250....................................................................................................................................... ...........................................................115-175 ft/lbs 1985-86 F250....................................................................................................................................... ...........................................................115-175 ft/lbs 1985-86 F350: Single Rear Wheels.............................................................................................................................. .......................................115-175 ft/lbs Dual Rear Wheels................................................................... ....................................................................................................125-155 ft/lbs 1983-86 Bronco.................................................................................................................................... ............................................................85-115 ft/lbs 1983-86 Bronco II................................................................................................................................. ............................................................85-115 ft/lbs 1983-86 Ranger.................................................................................................................................... .............................................................85-115 ft/lbs 1983-86 E100-250................................................................................................................................ ............................................................85-115 ft/lbs 1983-86 F100-250................................................................................................................................ .............................................................85-115 ft/lbs 1983-84 E350: Single Rear Wheels.............................................................................................................................. .......................................115-175 ft/lbs Dual Rear Wheels................................................................... ....................................................................................................175-260 ft/lbs 1983-84 F350: Single Rear Wheels.............................................................................................................................. .......................................115-175 ft/lbs Dual Rear Wheels................................................................... ....................................................................................................175-260 ft/lbs Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Door Actuator > Page 5461 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only Blower Motor: Customer Interest Auxiliary Blower Motor - Operates On High Only ^ AIR CONDITIONING - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY ^ HEATER - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY Article No. 88-20-13 LIGHT TRUCK: 1985-88 ECONOLINE ISSUE: An auxiliary blower motor that only operates in the high speed mode may be caused by an open thermal limiter on the auxiliary blower motor resistor. The current location of the resistor does not allow the thermal limiter to properly cool. ACTION: Install a new blower motor resistor in a new location to achieve better cooling of the thermal limiter. Refer to the following service procedure for removal and installation instructions. 1. Remove the auxiliary "A/C-Heater" or "Heater" cover assembly. 2. Disconnect the blower motor resistor wiring connectors. 3. Remove the resistor and two (2) mounting clips from the resistor mounting posts. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only > Page 5470 FIGURE 7 4. Cut out the template, Figure 7. FIGURE 8 5. Position the template on the plastic case as shown in Figure 8. 6. Scribe the plastic case to correctly locate the resistor opening and two (2) mounting screw holes. 7. Cut the resistor opening with a hot knife or a saw. Using a 5/32" drill bit, drill the two (2) new mounting screw holes. 8. Install the two (2) resistor mounting clips removed in Step 3 over the new mounting screw holes. 9. Position the new blower motor resistor, (E8UZ- 19A706-A) with the windings facing upward. FIGURE 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only > Page 5471 10. Install the two (2) mounting screws, Figure 9. NOTE: MAKE SURE THE BLOWER MOTOR RESISTOR COILS OR COIL TERMINALS ARE NOT TOUCHING THE PLASTIC CASE. ADJUST THE MOUNTING LOCATION IF NECESSARY. 11. Reconnect the blower motor resistor wiring connectors. 12. Make sure the auxiliary blower motor operates at each speed mode. 13. Reinstall the auxiliary "A/C-Heater" or "Heater" cover assembly. PART NUMBER PART NAME CLASS E8UZ-19A706-A Resistor-Blower Motor B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 882013A TIME: 0.7 Hr. DLR. CODING: Basic Part No. 19A706 Condition Code: 46 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5476 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only Blower Motor: All Technical Service Bulletins Auxiliary Blower Motor - Operates On High Only ^ AIR CONDITIONING - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY ^ HEATER - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY Article No. 88-20-13 LIGHT TRUCK: 1985-88 ECONOLINE ISSUE: An auxiliary blower motor that only operates in the high speed mode may be caused by an open thermal limiter on the auxiliary blower motor resistor. The current location of the resistor does not allow the thermal limiter to properly cool. ACTION: Install a new blower motor resistor in a new location to achieve better cooling of the thermal limiter. Refer to the following service procedure for removal and installation instructions. 1. Remove the auxiliary "A/C-Heater" or "Heater" cover assembly. 2. Disconnect the blower motor resistor wiring connectors. 3. Remove the resistor and two (2) mounting clips from the resistor mounting posts. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only > Page 5482 FIGURE 7 4. Cut out the template, Figure 7. FIGURE 8 5. Position the template on the plastic case as shown in Figure 8. 6. Scribe the plastic case to correctly locate the resistor opening and two (2) mounting screw holes. 7. Cut the resistor opening with a hot knife or a saw. Using a 5/32" drill bit, drill the two (2) new mounting screw holes. 8. Install the two (2) resistor mounting clips removed in Step 3 over the new mounting screw holes. 9. Position the new blower motor resistor, (E8UZ- 19A706-A) with the windings facing upward. FIGURE 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only > Page 5483 10. Install the two (2) mounting screws, Figure 9. NOTE: MAKE SURE THE BLOWER MOTOR RESISTOR COILS OR COIL TERMINALS ARE NOT TOUCHING THE PLASTIC CASE. ADJUST THE MOUNTING LOCATION IF NECESSARY. 11. Reconnect the blower motor resistor wiring connectors. 12. Make sure the auxiliary blower motor operates at each speed mode. 13. Reinstall the auxiliary "A/C-Heater" or "Heater" cover assembly. PART NUMBER PART NAME CLASS E8UZ-19A706-A Resistor-Blower Motor B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 882013A TIME: 0.7 Hr. DLR. CODING: Basic Part No. 19A706 Condition Code: 46 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5488 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 5489 Blower Motor: Locations Attached To RH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 Fig. 32 Heater Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 5494 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations LH Side Of Dash LH Corner Of Engine Compartment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Resistor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only Blower Motor Resistor: Customer Interest Auxiliary Blower Motor - Operates On High Only ^ AIR CONDITIONING - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY ^ HEATER - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY Article No. 88-20-13 LIGHT TRUCK: 1985-88 ECONOLINE ISSUE: An auxiliary blower motor that only operates in the high speed mode may be caused by an open thermal limiter on the auxiliary blower motor resistor. The current location of the resistor does not allow the thermal limiter to properly cool. ACTION: Install a new blower motor resistor in a new location to achieve better cooling of the thermal limiter. Refer to the following service procedure for removal and installation instructions. 1. Remove the auxiliary "A/C-Heater" or "Heater" cover assembly. 2. Disconnect the blower motor resistor wiring connectors. 3. Remove the resistor and two (2) mounting clips from the resistor mounting posts. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Resistor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only > Page 5506 FIGURE 7 4. Cut out the template, Figure 7. FIGURE 8 5. Position the template on the plastic case as shown in Figure 8. 6. Scribe the plastic case to correctly locate the resistor opening and two (2) mounting screw holes. 7. Cut the resistor opening with a hot knife or a saw. Using a 5/32" drill bit, drill the two (2) new mounting screw holes. 8. Install the two (2) resistor mounting clips removed in Step 3 over the new mounting screw holes. 9. Position the new blower motor resistor, (E8UZ- 19A706-A) with the windings facing upward. FIGURE 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor Resistor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only > Page 5507 10. Install the two (2) mounting screws, Figure 9. NOTE: MAKE SURE THE BLOWER MOTOR RESISTOR COILS OR COIL TERMINALS ARE NOT TOUCHING THE PLASTIC CASE. ADJUST THE MOUNTING LOCATION IF NECESSARY. 11. Reconnect the blower motor resistor wiring connectors. 12. Make sure the auxiliary blower motor operates at each speed mode. 13. Reinstall the auxiliary "A/C-Heater" or "Heater" cover assembly. PART NUMBER PART NAME CLASS E8UZ-19A706-A Resistor-Blower Motor B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 882013A TIME: 0.7 Hr. DLR. CODING: Basic Part No. 19A706 Condition Code: 46 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only Blower Motor Resistor: All Technical Service Bulletins Auxiliary Blower Motor - Operates On High Only ^ AIR CONDITIONING - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY ^ HEATER - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY Article No. 88-20-13 LIGHT TRUCK: 1985-88 ECONOLINE ISSUE: An auxiliary blower motor that only operates in the high speed mode may be caused by an open thermal limiter on the auxiliary blower motor resistor. The current location of the resistor does not allow the thermal limiter to properly cool. ACTION: Install a new blower motor resistor in a new location to achieve better cooling of the thermal limiter. Refer to the following service procedure for removal and installation instructions. 1. Remove the auxiliary "A/C-Heater" or "Heater" cover assembly. 2. Disconnect the blower motor resistor wiring connectors. 3. Remove the resistor and two (2) mounting clips from the resistor mounting posts. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only > Page 5513 FIGURE 7 4. Cut out the template, Figure 7. FIGURE 8 5. Position the template on the plastic case as shown in Figure 8. 6. Scribe the plastic case to correctly locate the resistor opening and two (2) mounting screw holes. 7. Cut the resistor opening with a hot knife or a saw. Using a 5/32" drill bit, drill the two (2) new mounting screw holes. 8. Install the two (2) resistor mounting clips removed in Step 3 over the new mounting screw holes. 9. Position the new blower motor resistor, (E8UZ- 19A706-A) with the windings facing upward. FIGURE 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Resistor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only > Page 5514 10. Install the two (2) mounting screws, Figure 9. NOTE: MAKE SURE THE BLOWER MOTOR RESISTOR COILS OR COIL TERMINALS ARE NOT TOUCHING THE PLASTIC CASE. ADJUST THE MOUNTING LOCATION IF NECESSARY. 11. Reconnect the blower motor resistor wiring connectors. 12. Make sure the auxiliary blower motor operates at each speed mode. 13. Reinstall the auxiliary "A/C-Heater" or "Heater" cover assembly. PART NUMBER PART NAME CLASS E8UZ-19A706-A Resistor-Blower Motor B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 882013A TIME: 0.7 Hr. DLR. CODING: Basic Part No. 19A706 Condition Code: 46 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical Service Bulletins > Page 5515 Blower Motor Resistor: Locations Part Of Blower Motor Assembly Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Auxiliary Blower Switch > Page 5520 Blower Motor Switch: Locations Front Blower Switch LH Side Of Control Assembly Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Component Information > Diagrams > Diagram Information and Instructions Compressor HVAC: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 5525 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 872019 > Oct > 87 > A/C Condenser Outlet Tube - Refrigerant Leak Condenser HVAC: Customer Interest A/C Condenser Outlet Tube - Refrigerant Leak Article No. AIR CONDITIONING - LEAKS REFRIGERANT 87-20-19 CONDENSER OUTLET TUBE CRACKED LIGHT TRUCK: 1984-87 ECONOLINE ISSUE: Refrigerant leaks at the condenser outlet tube to the receiver/drier fitting may be caused by a fitting that was overtightened during production. The overtightening of the fitting may cause the condenser outlet tube to crack. ACTION: To correct this, install a new condenser outlet tube. Torque the outlet tube to receiver/drier fitting to 5-10 ft.lbs. (7-13 N-m). NOTE: It is not necessary to replace the condenser assembly. PART NUMBER PART NAME CLASS E4UZ-19835-A Condenser Outlet Tube B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP872019A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 19835 - Code: 01 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures Condenser HVAC: All Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures > Page 5539 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 872019 > Oct > 87 > A/C Condenser Outlet Tube Refrigerant Leak Condenser HVAC: All Technical Service Bulletins A/C Condenser Outlet Tube - Refrigerant Leak Article No. AIR CONDITIONING - LEAKS REFRIGERANT 87-20-19 CONDENSER OUTLET TUBE CRACKED LIGHT TRUCK: 1984-87 ECONOLINE ISSUE: Refrigerant leaks at the condenser outlet tube to the receiver/drier fitting may be caused by a fitting that was overtightened during production. The overtightening of the fitting may cause the condenser outlet tube to crack. ACTION: To correct this, install a new condenser outlet tube. Torque the outlet tube to receiver/drier fitting to 5-10 ft.lbs. (7-13 N-m). NOTE: It is not necessary to replace the condenser assembly. PART NUMBER PART NAME CLASS E4UZ-19835-A Condenser Outlet Tube B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP872019A TIME: 0.9 Hr. DLR. CODING: Basic Part No. 19835 - Code: 01 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Condenser HVAC: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures Condenser HVAC: All Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Condenser HVAC: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures > Page 5549 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings A/C Coupler O-ring: Technical Service Bulletins A/C - New Refrigerant O-Rings Article No. 91-22-5 10/30/91 AIR CONDITIONING - NEW REFRIGERANT FITTING "O" RINGS (GREEN COLOR) AVAILABLE TO PROVIDE IMPROVED SEALING AND DURABILITY FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-92 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1991-92 TRACER LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-92 AEROSTAR 1988-92 F SUPER DUTY 1989-92 F-47 1991-92 EXPLORER ISSUE: New refrigerant 0-rings (GREEN COLOR) are available for use in the Ford Spring Lock Coupling (SLC) and threaded (Tube-0) connections. The new GREEN COLORED 0-ring material provides improved sealing and longer seal life. Use of any other 0-ring for Ford refrigerant fittings is not recommended and may result in premature leakage at the fitting. ACTION: If a refrigerant system repair is made which requires an A/C fitting to be disconnected, replace the existing 0-rings with the new GREEN COLORED type. Refer to the following 0-ring Usage Chart for identifying the correct 0-ring. O-RING USAGE CHART (SLC) (SLC) (TUBE-0) (TUBE-0) MOTORCRAFT SERVICE MOTORCRAFT SERVICE SIZE PART NO. PART NO. PART NO. PART NO. 3/8" YF-1753 391302-S100 YF-1753 391302-S100 1/2" YF-1754 391303-S100 YF-1754 391303-S100 5/8" YF-1755 391304-S100 YF-1756 391306-S100 3/4" YF-1752 3913O5-S100 YF-1757 391307-S100 PART NUMBER PART NAME CLASS 391302-S100 3/8" 0-ring (SLC & TUBE-0, S Pkg./6) 391303-S100 1/2" 0-ring (SLC & TUBE-0, S Pkg./6) 391304-S100 5/8" 0-ring (SLC, Pkg./6) S 391306-S100 5/8" 0-ring (TUBE-0, Pkg./6) S 391305-S100 3/4" 0-ring (SLC, Pkg./6) S 391307-S100 3/4" 0-ring (TUBE-0, Pkg./4) S OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-14-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings > Page 5555 A/C Coupler O-ring: Technical Service Bulletins A/C - Spring Lock Coupling Service Article No. 85-6-2 AIR CONDITIONING - SERVICING OF SPRING LOCK COUPLING GARTER SPRING AND O-RING FORD 1983-1985 MUSTANG, THUNDERBIRD, GRANADA, FAIRMONT, LTD, TEMPO, ESCORT, EXP LINCOLN-MERCURY 1983-1985 CAPRI, COUGAR, ZEPHYR, MARQUIS, CONTINENTAL MARK VII, TOPAZ, LYNX, LN7 LIGHT TRUCK 1983-1985 ECONOLINE, RANGER, BRONCO II Some A/C system components are being replaced only because the garter springs in the spring lock coupling cages are missing. If these components are otherwise not faulty, they should not be replaced; the missing parts should simply be installed. Replacement spring or O-ring part numbers are listed in the Parts catalog and should be used in these situations. Listed below are garter spring and O-ring part numbers currently available. PART NUMBER PART NAME CLASS E1ZZ-19E576-A 3/8 in. Garter Spring RM E1ZZ-19E576-B 1/2 in. Garter Spring RM E35Y-19E576-A 5/8 in. Garter Spring B 390209-S 3/4 in. O-Ring S E1ZZ-19B596-A O-Ring Kit B Contains: 6 - 389157 - 3/8 in. O-Rings 6 - 389157 - 1/2 in. O-Rings E35Y-19D690-A O-Ring and Garter Spring Kit Contains: A 24 - 389157 - 3/8 in. O-Rings 24 - 389158 - 1/2 in. O-Rings 24 - 389623 5/8 in. O-Rings 6 - E1ZZ-19E576-A 3/8 in. Garter Spring 6 - E1ZZ-19E576-B 1/2 in. Garter Spring 6 E35Y-19E576-A 5/8 in. Garter Spring The service kits are intended as a convenience for service personnel and not for warranty claims. Use the number of the specific part used on warranty claims. NOTE: Only the specified O-Rings should be used as they are made of a special rubber compound. WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler Spring > Component Information > Technical Service Bulletins > A/C - Spring Lock Coupling Service A/C Coupler Spring: Technical Service Bulletins A/C - Spring Lock Coupling Service Article No. 85-6-2 AIR CONDITIONING - SERVICING OF SPRING LOCK COUPLING GARTER SPRING AND O-RING FORD 1983-1985 MUSTANG, THUNDERBIRD, GRANADA, FAIRMONT, LTD, TEMPO, ESCORT, EXP LINCOLN-MERCURY 1983-1985 CAPRI, COUGAR, ZEPHYR, MARQUIS, CONTINENTAL MARK VII, TOPAZ, LYNX, LN7 LIGHT TRUCK 1983-1985 ECONOLINE, RANGER, BRONCO II Some A/C system components are being replaced only because the garter springs in the spring lock coupling cages are missing. If these components are otherwise not faulty, they should not be replaced; the missing parts should simply be installed. Replacement spring or O-ring part numbers are listed in the Parts catalog and should be used in these situations. Listed below are garter spring and O-ring part numbers currently available. PART NUMBER PART NAME CLASS E1ZZ-19E576-A 3/8 in. Garter Spring RM E1ZZ-19E576-B 1/2 in. Garter Spring RM E35Y-19E576-A 5/8 in. Garter Spring B 390209-S 3/4 in. O-Ring S E1ZZ-19B596-A O-Ring Kit B Contains: 6 - 389157 - 3/8 in. O-Rings 6 - 389157 - 1/2 in. O-Rings E35Y-19D690-A O-Ring and Garter Spring Kit Contains: A 24 - 389157 - 3/8 in. O-Rings 24 - 389158 - 1/2 in. O-Rings 24 - 389623 5/8 in. O-Rings 6 - E1ZZ-19E576-A 3/8 in. Garter Spring 6 - E1ZZ-19E576-B 1/2 in. Garter Spring 6 E35Y-19E576-A 5/8 in. Garter Spring The service kits are intended as a convenience for service personnel and not for warranty claims. Use the number of the specific part used on warranty claims. NOTE: Only the specified O-Rings should be used as they are made of a special rubber compound. WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5568 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 (V8-302 5.0L (1985)) 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 5569 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 (V8-302 5.0L (1985)) 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 5570 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 (V8-302 5.0L (1985)) 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 5571 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 (V8-302 5.0L (1985)) 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 5572 Figure 25 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5573 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 (V8-302 5.0L (1985)) 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 5574 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 (V8-302 5.0L (1985)) 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 5575 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 (V8-302 5.0L (1985)) 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 5576 Figure 29 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5577 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 (V8-302 5.0L (1985)) 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 5578 Figure 30 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5579 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 (V8-302 5.0L (1985)) 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 5580 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 (V8-302 5.0L (1985)) 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 5581 Figure 31 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5582 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 (V8-302 5.0L (1985)) 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 5583 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5588 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 (V8-302 5.0L (1985)) 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 5589 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5590 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 (V8-302 5.0L (1985)) 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 5591 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 (V8-302 5.0L (1985)) 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 5592 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 (V8-302 5.0L (1985)) 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 5593 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 (V8-302 5.0L (1985)) 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 5594 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5600 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 (V8-302 5.0L (1985)) 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 5601 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 (V8-302 5.0L (1985)) 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 5602 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 (V8-302 5.0L (1985)) 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 5603 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 (V8-302 5.0L (1985)) 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 5604 Figure 25 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5605 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 (V8-302 5.0L (1985)) 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 5606 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 (V8-302 5.0L (1985)) 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 5607 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 (V8-302 5.0L (1985)) 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 5608 Figure 29 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5609 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 (V8-302 5.0L (1985)) 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 5610 Figure 30 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5611 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 (V8-302 5.0L (1985)) 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 5612 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 (V8-302 5.0L (1985)) 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 5613 Figure 31 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5614 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 (V8-302 5.0L (1985)) 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 5615 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5620 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 (V8-302 5.0L (1985)) 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 5621 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5622 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 (V8-302 5.0L (1985)) 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 5623 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 (V8-302 5.0L (1985)) 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 5624 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 (V8-302 5.0L (1985)) 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 5625 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 (V8-302 5.0L (1985)) 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 5626 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures Evaporator Core: Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures > Page 5631 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5640 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 (V8-302 5.0L (1985)) 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 5641 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5642 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 (V8-302 5.0L (1985)) 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 5643 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 (V8-302 5.0L (1985)) 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 5644 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 (V8-302 5.0L (1985)) 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 5645 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 (V8-302 5.0L (1985)) 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 5646 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5651 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 (V8-302 5.0L (1985)) 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 5652 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 (V8-302 5.0L (1985)) 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 5653 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 (V8-302 5.0L (1985)) 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 5654 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 (V8-302 5.0L (1985)) 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 5655 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 (V8-302 5.0L (1985)) 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 5656 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 (V8-302 5.0L (1985)) 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 5657 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 (V8-302 5.0L (1985)) 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 5658 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 (V8-302 5.0L (1985)) 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 5659 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5665 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 (V8-302 5.0L (1985)) 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 5666 Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 5667 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 (V8-302 5.0L (1985)) 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 5668 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 (V8-302 5.0L (1985)) 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 5669 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 (V8-302 5.0L (1985)) 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 5670 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 (V8-302 5.0L (1985)) 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 5671 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 5676 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 (V8-302 5.0L (1985)) 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 5677 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 (V8-302 5.0L (1985)) 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 5678 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 (V8-302 5.0L (1985)) 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 5679 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 (V8-302 5.0L (1985)) 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 5680 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 (V8-302 5.0L (1985)) 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 5681 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 (V8-302 5.0L (1985)) 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 5682 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 (V8-302 5.0L (1985)) 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 5683 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 (V8-302 5.0L (1985)) 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 5684 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 5695 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 5696 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 5697 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 5698 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5703 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5704 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5705 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5706 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 5712 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 5713 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 5714 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 5715 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 5720 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 5721 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 5722 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Substitutes Service Tip Article No. 96-17-10 08/12/96 AIR CONDITIONING - USE OF R-12 REFRIGERANT SUBSTITUTES - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 COUGAR 1982-94 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1985-94 CARGO SERIES, F & B SERIES, L SERIES This TSB article is being republished in its entirety to list Environmental Protection Agency (EPA) reviewed NC substitutes for R-12 refrigerant. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. ACTION: If service is required, use only new or of known quality recycled refrigerant R-12. Ford Motor Company has approved R-134a as the only refrigerant substitute for R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. INFORMATION FROM THE EPA Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 5727 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 5728 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components. ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time. R-134a is approved only for systems which specify R-134a, Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes > Page 5733 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 93206 > Sep > 93 > Air Conditioning - Use of Correct Fluorescent Tracer Dye Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 9197 > May > 91 > A/C - R12 Refrigerant Service Tips Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Service Tips Article No. 91-9-7 05/01/91 AIR CONDITIONING - REFRIGERANT R-12 - SERVICE TIPS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK: 1985-90 C SERIES 1985-91 CL-CLT-9000 SERIES, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for Refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C components. ACTION: If service is required, use only NEW or RECYCLED Refrigerant R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5742 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5743 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5744 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5745 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5746 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5747 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 5748 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5751 Refrigerant: Fluid Type Specifications Type ..................................................................................................................................................... ............................................... Refrigerant 12 (R-12) Ford Part Number ............................................. ........................................................................................................................................ D4AZ-19B519-A Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 5756 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 5757 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 5758 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5763 Refrigerant Oil: Fluid Type Specifications Compressor ................................................................................................................... 500 viscosity (C9AZ-19557-B or Motorcraft VN-2 or equivalent) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations LH Side Of Dash LH Corner Of Engine Compartment Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Auxiliary Blower Switch > Page 5773 Blower Motor Switch: Locations Front Blower Switch LH Side Of Control Assembly Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations > Temperature Selector Vacuum Connection Block > Page 5781 Vacuum Harness HVAC: Locations Function Control Vacuum Connection Block Behind I/P Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations > Page 5782 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Tank <--> [Vacuum Reservoir HVAC] > Component Information > Description and Operation > Page 5786 Vacuum Tank: Service and Repair 1983-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect the two vacuum lines connected to the reservoir ports. 2. Remove reservoir retaining nuts from the underside of the left hand apron, then the reservoir. 3. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 5796 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 5797 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 5798 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 5799 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 5800 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 5801 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 5802 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Seat Belt - Service Kit For Front Outboard Tongue Seat Belt Buckle: Technical Service Bulletins Seat Belt - Service Kit For Front Outboard Tongue Article No. 93-12-1 06/09/93 SEAT BELT - FRONT - AVAILABILITY OF NEW SERVICE KIT FOR OUTBOARD TONGUE FORD: 1984-85 CROWN VICTORIA, ESCORT, EXP, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1984-85 CONTINENTAL, COUGAR, GRAND MARQUIS, LYNX, MARK VII, TOPAZ, TOWN CAR LIGHT TRUCK: 1984-85 ECONOLINE, F-150-350 SERIES ISSUE: A new service kit is now available for replacing the front seat belt outboard tongue assemblies as used on the subject vehicles. Previously, if service was required for the outboard tongue, the complete seat belt assembly had to be replaced. ACTION: If service to the front seat belt outboard tongue is required, use the new service kit (E4ZZ-61610D94-A) and refer to the installation instructions provided is the kit (I.S.6252A). The kit contains a pre-assembled tongue assembly. PART NUMBER PART NAME CLASS E4ZZ-61610D94-A Seat Belt Tongue Service Kit (2 C Req.) E7FZ-61612A64-A Tongue Cover (Not Included In B Kit) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 92-2-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 104000, 190000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > System Information > Technical Service Bulletins > Antitheft Devices - Installation Precautions > Page 5823 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5838 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5839 Fig. 8 Camper & Trailer Option Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5847 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 5848 Fig. 8 Camper & Trailer Option Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Door Latches - Adjustment/Modification Prohibition Front Door Latch: Technical Service Bulletins Door Latches - Adjustment/Modification Prohibition Article No. 91-8-4 04/17/91 LATCHES - DOOR - REPLACEMENT REQUIRED FORD: 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK:1985-90 C SERIES 1985-91 CL-9000, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: Rework of door latches has been reported from Service Investigation Reports. This is unacceptable as it may affect proper latch function. ACTION: Replace latches which function improperly and can not be adjusted. WARNING: NEVER REWORK OR MODIFY A LATCH ASSEMBLY, ALWAYS REPLACE THE LATCH ASSEMBLY. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Door Latches - Adjustment/Modification Prohibition Rear Door Latch: Technical Service Bulletins Door Latches - Adjustment/Modification Prohibition Article No. 91-8-4 04/17/91 LATCHES - DOOR - REPLACEMENT REQUIRED FORD: 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK:1985-90 C SERIES 1985-91 CL-9000, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: Rework of door latches has been reported from Service Investigation Reports. This is unacceptable as it may affect proper latch function. ACTION: Replace latches which function improperly and can not be adjusted. WARNING: NEVER REWORK OR MODIFY A LATCH ASSEMBLY, ALWAYS REPLACE THE LATCH ASSEMBLY. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction Sliding Door: Customer Interest Body/Frame - Water Leak Identification and Correction Article No. 92-9-10 04/22/92 LEAKS WATER - IDENTIFICATION AND CORRECTION LIGHT TRUCK: 1984-91 ECONOLINE This TSB Article was originally published as TSB 84-19-15 on September 12, 1984. It is being republished because the basic water leak corrective procedures and techniques remain applicable for the more recent models as well. ISSUE: The water leak identification and correction procedures outlined in this article are the most common conditions you may encounter. It is unlikely that you will ever find it necessary to perform all of the possible corrections on a single vehicle. Each vehicle is unique and, therefore, careful attention is required in evaluating the vehicle and making the necessary corrections. ACTION: If service is required, use the following procedure to identify and correct the water leaks. DIAGNOSING WATER LEAKS The actual sources of these various water leaks may often be misleading. ^ The spot where the water shows up is not always the location of the trouble. ^ Do not always rely on the service order, or even the customer, to pinpoint the actual leak area. ^ The description of the water leak will usually reflect only where the water is noticeable, not necessarily where the cause is located. GENERAL TEST PROCEDURES Although every dealership has its own method for testing water leaks, the following methods will be helpful to the technician in solving the more difficutt and persistent water leaks. NOTE: DETECTION OF WATER LEAKS IN THE REAR CARGO FLOOR AREA MAY BE ENHANCED BY PLACING A LARGE LIGHT BULB IN THE CARGO AREA, RAISING THE VEHICLE ON A HOIST AND CHECKING THE FLOOR PAN JOINT FOR ANY LIGHT SHINING THROUGH. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5870 LOCATION OF "WET AREAS Areas to examine for potential wet spots are shown in Figure 1 and are described as follows: a. Front Door Step Well b. Base of "B" Pillar on Floor c. Side Door Step Well d. Base of "C" Pillar on Floor e. Forward of Rear Wheelhouse on Floor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5871 f. Behind Rear Wheelhouse on Floor g. Around Fuel Filler Housing on Floor h. Base of Rear Cargo Doors on Floor i. Rear Corners of Floor j. Miscellaneous - All Window and Door Weatherstrips SEALING MATERIALS A list of sealing materials is shown below. 1. Silicone Rubber Adhesive ^ Clear - Ford (D6AZ-19562-AA) or 3M 08661 ^ Black - Ford (D6AZ-19562-BA) or 3M 08662 These are rapid curing adhesives/sealants formulated for such uses as sealing leaks, remounting trim and servicing torn weatherstripping adheres to a wide variety of surfaces. 2. Weatherstrip Adhesive ^ Yellow Colored - Ford (E8AZ-19552-A) This adhesive holds weatherstripping on doors, bodies, cowl ventilators and other locations. It is used to service loose weatherstripping or install new weatherstripping. It is also used to bond numerous rubber-to-metal, rubber-to-wood, rubber-to-cardboard and rubber-to-rubber surfaces. It stops leaks in windows set in rubber mouldings. It sets up fast. 3. Joint and Seam Sealer ^ White - 3M 08646 (Cartridge Type) ^ Black - 3M 08648 (Cartridge Type) This joint and seam sealer is a firm setting, but flexible sealer for interior and exterior body joints and seams. Typical applications are in floor and wheelwell areas. It skins over quickly and can be painted in about 30 minutes. WET AREAS - ILLUSTRATIONS Water entry in the front door step well (Wet Area A) may be from the locations. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5872 ^ Header Joints "B" Pillar (RH/LH) - Figure 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5873 ^ Cowl Side - wheelhouse (RH/LH) - Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5874 ^ Underside - wheelhouse (RH/LH) - Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5875 ^ Vent Air Valve - Cowl Side Outer (RH) - Figure 5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5876 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5877 ^ Door and Vent Window Weatherstrips (RH/LH) - Figures 18-19 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5878 Water entry at the base of the "B" pillar on the floor (Wet Area B) may be from the "B" pillar to bodyside vertical seam (LH) - Figure 6. Water entry in the side door step well (Wet Area C) may be from the following locations. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5879 ^ Header Joint "B" Pillar (RH) - Figure 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5880 ^ Header Joint "C" Pillar (RH) - Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5881 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5882 ^ Door and Vent Window Weatherstrips (RH/LH) - Figures 18-19 Water entry at the base of the "C" pillar on the floor (Wet Area D) may be from the following locations. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5883 ^ Front Sliding Door Track Reinforcement (RH) - Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5884 ^ Drip Rail and Clips (RH/LH) - Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5885 ^ "C" Pillar to Bodyside Seam (RH) - Figure 7 Water entry forward of the rear wheelhouse (Wet Areas E and G) may be from the following locations. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5886 ^ Sliding Door Track Reinforcement to Bodyside (RH) - Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5887 ^ Sliding Door Track Reinforcement to Bodyside - Forward Pilot Hole (RH) - Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5888 ^ Drip Rail and Clips (RH/LH) - Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5889 ^ Underside of Wheelhouse to Bodyside Along Radius (RH/LH) - Figure 11 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5890 ^ Fuel Filler Housing - Auxiliary Tank (LH) - Figure 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5891 ^ Auxiliary Gas Filler Door Bumper Holes - Backside (LH) - Figure 14 ^ Auxiliary Fuel Filler Door Opening Flange (LH) - Figure 14 ^ Horizontal Flange Inside of Fuel Filler Opening (LH) - Figure 14 Water entry behind the rear wheelhouse and rear corners of floor (Wet Area F and 1) may be from the following locations. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5892 ^ Underside of Wheelhouse to Bodyside Along Radius (RH/LH) - Figure 11 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5893 ^ Drip Rail and Clips (RH/LH) - Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5894 ^ Floor Pan to Wheelhouse at Ends - Topside and Underside (RH/LH) - Figure 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5895 ^ Side Marker Lamp (RH/LH) - Figure 17 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5896 ^ Rear End of Sliding Door Track (RH) - Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5897 ^ Sliding Door Track Reinforcement - Rearward Pilot Hole (RH) - Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5898 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5899 Water entry at the base of the rear cargo doors (Wet Areas H) may be from mispositioned trim filler blocks or the "D" pillar to quarter panel seam - Figures 15 and 16. PART NUMBER PART NAME CLASS D6AZ-19562-BA Silicone Rubber Sealer - Black B D6AZ-195662-AA Silicone Rubber Sealer - Clear B E8AZ-19552-A Weatherstrip Adhesive B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 84-19-15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > Customer Interest: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5900 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 111000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction Sliding Door: All Technical Service Bulletins Body/Frame - Water Leak Identification and Correction Article No. 92-9-10 04/22/92 LEAKS WATER - IDENTIFICATION AND CORRECTION LIGHT TRUCK: 1984-91 ECONOLINE This TSB Article was originally published as TSB 84-19-15 on September 12, 1984. It is being republished because the basic water leak corrective procedures and techniques remain applicable for the more recent models as well. ISSUE: The water leak identification and correction procedures outlined in this article are the most common conditions you may encounter. It is unlikely that you will ever find it necessary to perform all of the possible corrections on a single vehicle. Each vehicle is unique and, therefore, careful attention is required in evaluating the vehicle and making the necessary corrections. ACTION: If service is required, use the following procedure to identify and correct the water leaks. DIAGNOSING WATER LEAKS The actual sources of these various water leaks may often be misleading. ^ The spot where the water shows up is not always the location of the trouble. ^ Do not always rely on the service order, or even the customer, to pinpoint the actual leak area. ^ The description of the water leak will usually reflect only where the water is noticeable, not necessarily where the cause is located. GENERAL TEST PROCEDURES Although every dealership has its own method for testing water leaks, the following methods will be helpful to the technician in solving the more difficutt and persistent water leaks. NOTE: DETECTION OF WATER LEAKS IN THE REAR CARGO FLOOR AREA MAY BE ENHANCED BY PLACING A LARGE LIGHT BULB IN THE CARGO AREA, RAISING THE VEHICLE ON A HOIST AND CHECKING THE FLOOR PAN JOINT FOR ANY LIGHT SHINING THROUGH. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5906 LOCATION OF "WET AREAS Areas to examine for potential wet spots are shown in Figure 1 and are described as follows: a. Front Door Step Well b. Base of "B" Pillar on Floor c. Side Door Step Well d. Base of "C" Pillar on Floor e. Forward of Rear Wheelhouse on Floor Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5907 f. Behind Rear Wheelhouse on Floor g. Around Fuel Filler Housing on Floor h. Base of Rear Cargo Doors on Floor i. Rear Corners of Floor j. Miscellaneous - All Window and Door Weatherstrips SEALING MATERIALS A list of sealing materials is shown below. 1. Silicone Rubber Adhesive ^ Clear - Ford (D6AZ-19562-AA) or 3M 08661 ^ Black - Ford (D6AZ-19562-BA) or 3M 08662 These are rapid curing adhesives/sealants formulated for such uses as sealing leaks, remounting trim and servicing torn weatherstripping adheres to a wide variety of surfaces. 2. Weatherstrip Adhesive ^ Yellow Colored - Ford (E8AZ-19552-A) This adhesive holds weatherstripping on doors, bodies, cowl ventilators and other locations. It is used to service loose weatherstripping or install new weatherstripping. It is also used to bond numerous rubber-to-metal, rubber-to-wood, rubber-to-cardboard and rubber-to-rubber surfaces. It stops leaks in windows set in rubber mouldings. It sets up fast. 3. Joint and Seam Sealer ^ White - 3M 08646 (Cartridge Type) ^ Black - 3M 08648 (Cartridge Type) This joint and seam sealer is a firm setting, but flexible sealer for interior and exterior body joints and seams. Typical applications are in floor and wheelwell areas. It skins over quickly and can be painted in about 30 minutes. WET AREAS - ILLUSTRATIONS Water entry in the front door step well (Wet Area A) may be from the locations. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5908 ^ Header Joints "B" Pillar (RH/LH) - Figure 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5909 ^ Cowl Side - wheelhouse (RH/LH) - Figure 3 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5910 ^ Underside - wheelhouse (RH/LH) - Figure 4 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5911 ^ Vent Air Valve - Cowl Side Outer (RH) - Figure 5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5912 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5913 ^ Door and Vent Window Weatherstrips (RH/LH) - Figures 18-19 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5914 Water entry at the base of the "B" pillar on the floor (Wet Area B) may be from the "B" pillar to bodyside vertical seam (LH) - Figure 6. Water entry in the side door step well (Wet Area C) may be from the following locations. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5915 ^ Header Joint "B" Pillar (RH) - Figure 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5916 ^ Header Joint "C" Pillar (RH) - Figure 7 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5917 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5918 ^ Door and Vent Window Weatherstrips (RH/LH) - Figures 18-19 Water entry at the base of the "C" pillar on the floor (Wet Area D) may be from the following locations. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5919 ^ Front Sliding Door Track Reinforcement (RH) - Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5920 ^ Drip Rail and Clips (RH/LH) - Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5921 ^ "C" Pillar to Bodyside Seam (RH) - Figure 7 Water entry forward of the rear wheelhouse (Wet Areas E and G) may be from the following locations. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5922 ^ Sliding Door Track Reinforcement to Bodyside (RH) - Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5923 ^ Sliding Door Track Reinforcement to Bodyside - Forward Pilot Hole (RH) - Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5924 ^ Drip Rail and Clips (RH/LH) - Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5925 ^ Underside of Wheelhouse to Bodyside Along Radius (RH/LH) - Figure 11 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5926 ^ Fuel Filler Housing - Auxiliary Tank (LH) - Figure 12 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5927 ^ Auxiliary Gas Filler Door Bumper Holes - Backside (LH) - Figure 14 ^ Auxiliary Fuel Filler Door Opening Flange (LH) - Figure 14 ^ Horizontal Flange Inside of Fuel Filler Opening (LH) - Figure 14 Water entry behind the rear wheelhouse and rear corners of floor (Wet Area F and 1) may be from the following locations. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5928 ^ Underside of Wheelhouse to Bodyside Along Radius (RH/LH) - Figure 11 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5929 ^ Drip Rail and Clips (RH/LH) - Figure 9 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5930 ^ Floor Pan to Wheelhouse at Ends - Topside and Underside (RH/LH) - Figure 13 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5931 ^ Side Marker Lamp (RH/LH) - Figure 17 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5932 ^ Rear End of Sliding Door Track (RH) - Figure 8 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5933 ^ Sliding Door Track Reinforcement - Rearward Pilot Hole (RH) - Figure 10 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5934 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5935 Water entry at the base of the rear cargo doors (Wet Areas H) may be from mispositioned trim filler blocks or the "D" pillar to quarter panel seam - Figures 15 and 16. PART NUMBER PART NAME CLASS D6AZ-19562-BA Silicone Rubber Sealer - Black B D6AZ-195662-AA Silicone Rubber Sealer - Clear B E8AZ-19552-A Weatherstrip Adhesive B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 84-19-15 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92910 > Apr > 92 > Body/Frame - Water Leak Identification and Correction > Page 5936 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 111000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sliding Door: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: All Technical Service Bulletins Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sliding Door: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 5942 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sliding Door: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 5948 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Frame Rivet Replacement with Bolts Service Tip Frame: Technical Service Bulletins Frame - Rivet Replacement with Bolts Service Tip Article No. 97-4-7 02/17/97 FRAME - RIVET REPLACEMENT WITH BOLTS - SERVICE TIPS LIGHT TRUCK: 1980-96 BRONCO 1980-97 ECONOLINE, F-150-350 SERIES 1983-97 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F SUPER DUTY, F-47 1991-97 EXPLORER This TSB article is being republished in its entirety to include 1997 model year vehicles. ISSUE: Damaged or loose frame rivets should be replaced with approved service bolts. WELDING IS NOT ACCEPTABLE. ACTION: If service is required, replace standard rivets with approved service bolts. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: THE "HUCK" RIVET BETWEEN THE # 1 CROSSMEMBER AND THE LH FRAME RAIL SHOULD BE SERVICED PER TSB 91-25-18. THIS PROCEDURE DOES NOT APPLY. 1. Inspect for a loose or damaged rivet. 2. Remove any damaged or loose rivets. a. Drill a 3.175 mm (1/8") hole through the rivet. b. Redrill the same hole through the shank of the rivet. ^ Use an 8.731 mm (11/32") drill for 3/8" and 10 mm rivets. ^ Use a 9.525 mm (3/8") drill for 11.113 mm (7/16") rivets. c. Remove the rivet head with an air chisel. d. Drive out the rivet with a punch and hammer. 3. Line ream the hole to the replacement bolt nominal size with a hole tolerance of +/- 0.127 mm (0.005"). 4. Free hole of burrs after reaming to allow bolt head and nut to seat properly. 5. Select the bolt length to have a minimum of two (2) threads protruding from outer face of nut. Refer to the following Bolt Selection Chart for correct parts usage. NOTE: IF A FLANGE HEAD NUT AND BOLT ARE NOT AVAILABLE, GRADE 5 HEX HEADS MAY BE SUBSTITUTED WITH ONE (1) FLATWASHER REQUIRED UNDER THE NUT AND ONE (1) FLATWASHER REQUIRED UNDER THE BOLT HEAD. 6. Check to be sure there is a 12.7 mm (1/2") minimum clearance of bolt to adjacent components, except engine and transmission, which must have at least 19.05 mm (3/4") clearance to allow for powertrain roll. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Frame Rivet Replacement with Bolts Service Tip > Page 5958 7. Tighten the bolts to the specifications shown in the Bolt Selection Chart. NOTE: GRADE 8 BOLTS MAY BE SUBSTITUTED FOR ANY APPLICATION. Parts Block OTHER APPLICABLE ARTICLES: 96-4-11 SUPERSEDES: 96-15-11 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-97 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 970407A Replace Rivet 0.5 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 5005 57 OASIS CODES: 304000, 305000, 390000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram Information and Instructions Door Locks: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram Information and Instructions > Page 5964 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram Information and Instructions > Page 5965 Door Locks: Electrical Diagrams Fig. 36 Power Door Locks Wiring Circuit (Part 1 of 2). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram Information and Instructions > Page 5966 Fig. 36 Power Door Locks Wiring Circuit (Part 2 of 2). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Page 5981 Power Door Lock Actuator: Locations Circuit Location Amps Power Door Locks .................Fuse Panel.....................30 Power Windows.....................In Line At Junction Block......20 Windshield Wiper..................Fuse Panel....................7.5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 5990 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 5991 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 5992 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 5993 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 5994 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 5995 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6001 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6002 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6003 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6004 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6005 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6006 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6011 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6012 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6013 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 6014 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures Technical Service Bulletin # 91181 Date: 910905 Exterior Paint - Comprehensive Repair Procedures Article No. 91-18-1 09/05/91 PAINT-EXTERIOR-COMPREHENSIVE REPAIR PROCEDURES FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-92 TAURUS 1988-92 FESTIVA 1989-92 PROBE LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1988-92 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-92 AEROSTAR 1991 EXPLORER ISSUE: A comprehensive paint repair procedure TSB has been developed for service use. It includes the following paint repair topics: Section (A) has been superseded by TSB # 9264, dated 3/92. (B) Exterior Color Peeling From Ultra Violet Light (C) Lower Body Stone Protection Repair Tips (D) Procedures For PVC Body Side Moldings (E) Lower Body-Side Stone Chip Protection Program (F) Surface Defect Removal Without Repainting (G) 1991 Color Matched/Compatible Spray Primer Chart (H) Repair For Tinted Clearcoat (I) Frequently Used And Paintable Plastics (J) 1992 Paint Codes ACTION: If paint repair is required, refer to the following procedures for paint restoration. Section A Has Been Superseded By TSB # 9264, Dated 3/92. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS PROCEDURE # 2 FINISH KARE FORMULA # 1119 AND # 883 (Buffered solution not as harsh on aluminum parts) WARNING: FOR YOUR SAFETY, USE RUBBER GLOVES, GOGGLES AND PROTECTIVE CLOTHING WHEN HANDLING THESE PRODUCTS. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6019 1. Apply hot diluted solution with soft mitt. 2. Agitate to create suds. Suds hold the acid solution in suspension and to the surface creating greater and extended activity. 3. Allow 3 to 5 minutes dwell time. 4. Rinse with COLD WATER. 5. Apply # 883 per label instructions. LIQUID NEUTRALIZER CONCENTRATE 1. Using a mitt, thoroughly go over the entire surface with the diluted solution (50-1) of water and # 118 Liquid Neutralizer Concentrate. Then wipe dry. 2. If the iron particles are not totally removed after 2 washings, use one or both of the following service actions. a. Sand with micro fine sandpaper (1500 Grid or greater) in localized areas. b. Buff with very light compound and polish with wax in localized areas. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'S) OR EXCESS MATERIALS. (B) Paint Exterior Color Peeling From Ultra Violet Light Paint may be damaged because of ultra violet light absorption through the color coat. This damage will cause the top coat to peel to the E-coat primer. If service is required, use the following procedure to correct the concerns. NOTE: READ THE ENTIRE SERVICE PROCEDURE BEFORE STARTING REPAIRS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT. 1. Wash the vehicle with soap and water. 2. Verify topcoat adhesion by applying a 2 inch wide masking tape strip on all body panels above and below the beltline on each panel. a. Pull the tape up quickly. b. Inspect the adhesive side of the tape for paint removal. NOTE: IF PAINT WAS REMOVED DURING THE TAPE TEST, THE ENTIRE PANEL SHOULD BE STRIPPED AND REFINISHED AS NECESSARY. 3. Remove all trim (mouldings, name plates, striping, etc.) from the areas which will be repainted. NOTE: ALL REQUIRED REPLACEMENT MOULDINGS AND STRIPES SHOULD BE ORDERED AND RECEIVED PRIOR TO REPAIRING THE CUSTOMER'S VEHICLE. 4. Wipe the entire vehicle with wax and grease remover. ^ BASF Product # 900 Prekleano ^ PPG Product # DX300 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mask off all areas on the vehicle which are not going to be painted or will be affected by overspray (engine compartment, wheels, etc.). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6020 6. Remove the paint to bare metal from all the areas of the vehicle which are going to be repainted. Use one of the following methods. SAND THE AFFECTED AREAS TO BARE METAL USING 40 GRIT 3M GREEN CORPS SANDING DISCS OR EQUIVALENT AND A SOFT PAD ON A 1700 RPM POLISHER. KEEP THE POLISHER MOVING TO AVOID DEVELOPING HOT SPOTS ON THE METAL. NOTE: CHEMICAL STRIPPING IS NOT RECOMMENDED. NOTE: IF AVAILABLE, PAINT MAY BE REMOVED USING A PLASTIC MEDIA BLAST SYSTEM. IF THIS PROCESS IS USED, EXTRA CARE MUST BE TAKEN DURING THE MASKING PROCESS TO PREVENT DAMAGE TO GLASS, MOULDING, ETC. 7. Blow off the entire vehicle to remove loose dust and debris. NOTE: IF RUST IS PRESENT, USE APPROPRIATE METAL CLEANER AND CONDITIONER (PHOSPHATE COATING) OVER BARE METAL AREAS. 8. Wipe all affected areas with a fast dry enamel reducer solvent, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. NOTE: THIS STEP WILL REDUCE THE POSSIBILITY OF FLASH RUST. ^ BASF Product # BR 50 ^ PPG Product # DX 300 ^ S-W Product # R7 K156 ^ DuPont Product # 3812 S ^ Sikkens Product # 123 FAST 9. Apply two medium wet coats (1.0 mil total) of self-etching, anti-corrosion primer using the manufacturer's recommendations and flash times. ^ BASF Product # DE-17 ^ PPG Product # DP EPOXY PRIMER ^ S-W Product # E2-6980 ^ DuPont Product # VARIPRIME ^ Sikkens Product # WASH FILLER 580 10. Apply three medium wet coats (2.0 mils total) of acrylic urethane primer surfacer following the manufacturer's recommended procedures. ^ BASF Product # DP-20 PRIMER/SUFACER ^ PPG Product # K-36 ^ S-W Product # P6-M49 OR P6-A48 ^ DuPont Product # URO PRIMERFILLER ^ Sikkens Product # AUTOCRYL 3+1 FILLER 11. Sand the vehicle using one of the following methods: ^ Wet-sand by hand using 400 grit or finer sandpaper. ^ Dry-sand by hand using 320 grit or finer sandpaper. 12. Blow the entire vehicle off to remove loose dust and debris. 13. Demask (remove all paper and tape) as necessary to remove the primer and dirt buildup on the paper and tape. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6021 14. Wipe the entire vehicle with wax and grease remover, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. ^ BASF Product # 901 PRE-PAINT CLEANER ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3812 S ^ Sikkens Product # M 600 15. Mask all areas on the vehicle which are not to be painted or will be affected by paint overspray (engine compartment, wheels, etc.). NOTE: APPLY BASECOAT/CLEAR COAT ONLY TO SURFACES WHICH ORIGINALLY HAD BASECOAT/CLEAR COAT 16. Apply three medium wet coats (enough material to hide primer) of acrylic enamel base coat or acrylic urethane monocoat following the manufacturer's recommended procedure. ^ BASF Product # DIAMONT BASECOAT/Solo ^ PPG Product # DELTRON BASECOAT DBC/Deltron ^ S-W Product # ULTRA BASE/Ultra One Stage ^ DuPont Product # CHROMABASE/Cronar ^ Sikkens Product # AUTO BASE/Autocryl 17. Apply two medium wet coats of 2K acrylic urethane enamel clear coat, following manufacturer's recommended procedure. ^ BASF Product # DIAMONT CLEAR 88/89 ^ PPG Product # CONCEPT 2001 DCU ^ S-W Product # CC-650 OR CC-640 ^ DuPont Product # 1080 S URO CLEAR ^ Sikkens Product # AUTO CLEAR 18. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray. 19. Polish the vehicle as necessary to remove any defects in the paint which may create a customer concern. CAUTION: USE LOW SPEED (1700 RPM MAXIMUM) POLISHER. 20. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior to repainting. 21. Clean the exterior and interior of the vehicle thoroughly, including air ducts and other areas which are prone to accumulating dust. This step is essential to ensure customer satisfaction. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6022 Figure 1 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6023 Figure 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6024 Figure 3 STRIP AND REFINISH CLAIMING METHODOLOGY The claiming instructions shown in Figure 1 are applicable to the repair of the EXTERIOR COLOR PEELING FROM ULTRA VIOLET LIGHT concern covered in this TSB only. See the SAMPLE CLAIMS, Figures 2 and 3, for examples. (C) Lower Body Stone Protection Repair Tips Ford has introduced a vinyl anti-stone abrasion material for the lower exterior body surfaces of selected passenger vehicles and light trucks. The anti-stone abrasion material is applied to the lower fenders, rocker panels, lower doors, quarter panel dogleg, and lower rear of quarter panel behind the wheel. The anti-stone abrasion material will usually end at a body character line. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6025 While primarily for servicing of factory-applied protective coating, the following provides installation information. If the vehicle has experienced body damage in the factory-applied material protective area, the sheet metal damage must be serviced prior to the application of the new protective coating. SMALL AREAS - MINOR DEFECTS (VEHICLES WITH FACTORY SPRAYED-ON VINYL) A small dent in the sheet metal that did not mar the vinyl surface, can possibly be corrected with proper bumping tools without damage to the vinyl coating. However, noticeable scratches or gouges (not over 1/2 inch in diameter) or dings and dents that when "ironed out" show vinyl damage, can be satisfactorily serviced with the following procedure: 1. Solvent-wipe the damaged area with "Silicone and Wax Remover." 2. Using a heat gun or lamp, soften the vinyl coating of the damaged area until it can be scraped off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The spray-on vinyl protective coatings may not be suitable for "spot" application. See Manufacturer's label for instructions.) 3. Perform necessary servicing to correct the sheet metal damage. 4. Using white bodyfiller, fill the damaged area. Follow the instructions on the label and blend the bodyfiller with the surrounding sheet metal. 5. Allow the bodyfiller to completely cure and then carefully sand the area smooth, removing any high spots. 6. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. LARGE DAMAGED AREAS - VEHICLE WITH FACTORY SPRAYED ON VINYL Peeling or damage over a large area will necessitate removal of the factory sprayed-on vinyl coating. The following procedure is suggested. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR, OR QUARTER PANEL REPLACEMENT IS REQUIRED (OR IN AN INITIAL INSTALLATION), DISREGARD STEPS NO. 1 AND NO. 2. 1. Using a heat gun or lamp, soften the vinyl coating until it is pliable. Scrape coating off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The vinyl material, abrasion resistant coating may not be suitable for "spot" applications. See manufacturer's label for instructions.) 2. Perform necessary servicing to correct the sheet metal damage. 3. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. COATING APPLICATIONS Approximately two quarts will be required for an initial installation on a passenger car or F-Series. Slightly more will be required for an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020 inch) will require at least three, possibly four, applications of coating material, with "flash off" time between coats. Spray coat complete panels only. The coating must be applied with commercial equipment by an experienced automotive painter. The coating must be thoroughly agitated before application. The material is heavy bodied. A pressure cup spray gun or "Rocker Schutz Gun" is recommended. COATING PREPARATION - MASKING VEHICLE Install suitable covers over the wheels. NOTE: IF THE VEHICLE HAS LOWER BODY SIDE MOULDINGS (12-14 INCHES ABOVE THE "TURN UNDER" OF THE ROCKER PANEL), THE MOULDING CAN SERVE AS THE UPPER MARGIN OF THE AREA TO BE COATED. IF THE VEHICLE DOES NOT HAVE SUITABLE MOULDINGS, A SCULPTURE OR BREAK LINE IN THE SHEET METAL CAN BE UTILIZED. THIS LINE SHOULD BE SELECTED TO ENSURE ADEQUATE PROTECTION OF THE PAINTED SURFACES. VEHICLES WITH BODY SIDE MOULDINGS 1. Masking tape should be positioned so that the moulding lower edge is also covered. The adjoining sheet metal should be left uncovered too so anti-stone, abrasion vinyl can be applied. VEHICLES WITHOUT BODY SIDE MOULDINGS 2. If the contour of the body side has a break line, the upper coating margin must be masked off using 3M "Fine Line" Tape. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6026 a. The normal masking tape and paper protection for the body side should be applied first and positioned about a quarter inch above the margin line. b. The "Fine Line" tape should then be applied over the regular masking tape with the lower edge at the upper coating margin line. Extend this "Fine Line" tape into the wheel opening, in the absence of wheel opening mouldings, allowing the flange to be coated. c. The anti-stone abrasion coating does not adhere well to flexible plastic parts. If left exposed, they must be masked off. d. It is not necessary to mask off the body door openings in the coating area, as they will be uniformly coated where the door margins allow the coating to enter. NOTE: DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. COATING PREPARATION - SHEET METAL REPAIRED SHEETMETAL 1. Scuff sand (No. 180 Grit Paper) the glossy surface of the painted areas to be coated. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and lint-free tack cloth. NEW SHEET METAL 1. Sand off (No. 180 Grit Paper) the prime paint in the area to be coated. 2. Using a lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. NEW INSTALLATION 1. The glossy surface of the paint in the coating area must be sanded with a D/A sander. A 220/240 Grit Disc does a good, fast job. DO NOT sand through the primer. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. SPRAY PROCEDURE The lower exposed painted fender, rocker, and quarter panel down flanges should be protected. The vehicle must be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote two-quart capacity pressure cup makes a much more efficient tool, as the spray gun can be used closer to the floor. The spray gun, fluid hose and/or cup must be cleaned immediately after use. Refer to manufacturer's recommended cleaning procedure. Lacquer thinner can be used when the suggested clean up material is unavailable. WARNING: WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EOUIPMENT. 1. After preparing the new or damaged area(s), mix either Epoxy primer or Self-etch prime, per manufacturer's label instructions, and spray bare metal areas. ^ BASF DE15 or DE17 ^ Sikkens Metalflex CR Primer (1 coat only) ^ DuPont Variprime ^ S-W E2G 980 GBP Etching Filler ^ PPG DP 40 (only) 2. Apply 1-2 light prime coats over the bare metal areas. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6027 3. Allow the material to dry for 15-20 minutes before applying the anti-stone abrasion material. 4. Mix and apply anti-stone abrasion material per manufacturer's label instructions over the primed area. NOTE: AN ORANGE PEELED FINISH IS NORMAL WITH THESE PRODUCTS. ^ BASF Glassohyd 1109-1240/6 ^ Sikkens 0TO Bodycoat ^ DuPont 123-5 Vinyl ^ S-W G/W 295 Vinyl Gravel Guard ^ PPG DX 54 Roadguard ^ 3M Rocker Schutz NOTE: SOME ANTI-STONE ABRASION MATERIAL MAY REQUIRE A SLIGHTLY DIFFERENT MIXING PREPARATION, PROCEDURE AND APPLICATION. SOME ANTI-STONE ABRASION MATERIALS CAN NOT BE USED FOR SPOT REPAIR. CHECK WITH THE PAINT MANUFACTURER FOR RECOMMENDATIONS ABOUT THEIR PRODUCT. 5. Allow the stone abrasion material to dry. Heat can be used to accelerate the drying time. Check the manufacturer's instructions. COLOR COAT The complete coated area, as well as the upper raw edge, must be covered with color coat. Mask off the upper margin line using "Fine Line" tape positioned 1/16 inch above the coating edge. Using appropriate service paint and application procedures, the protective coating area can now be finish painted with monocoat or a basecoat/clearcoat urethane system. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Figure 4 Refer to the Lower Body Stone Protection Chart, Figure 4, for the material and labor hours involved. (D) Procedure For PVC Body Side Moldings If replacement of the body side molding is necessary, some dealer service kits will be supplied "paint to match." Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6028 The painting procedures in the following instructions (also included with the part) address materials from five (5) major aftermarket paint suppliers. Use the paint system materials you are the most familiar with. NOTE: CAREFULLY READ ALL LABEL WARNINGS BEFORE APPLYING THESE PRODUCTS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SIKKENS PRODUCTS PREPARATION 1. Degrease with M600 wax and grease remover. 2. Scuff with # 320 dry paper or Scotchbrite 7447 (red). 3. Repeat degreasing step. 4. Spray two medium coats of Plastoflex primer. Allow 5 to 10 minutes flash between coats. 5. Allow 20 minutes flash-off at 70~ F before topcoating. TOPCOATING 1. Mix Autocryl color with Elast-O-Actif 50:50 by volume. 2. Mix this material with 1.2.3 hardner and 1.2.3 reducer (use correct reducer for temperature) 100:50:30 by volume. 3. Apply three medium coats, allowing enough flash off to dry to a light touch. 4. Dry one hour at 140~F after 10 minutes flash off or dry 24 hours at 75~F. PPG PRODUCTS PPG MONO-COAT SYSTEMS 1. Solvent wipe with DX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron topcoat color with DX-369 Flexative per label instructions. 2. Use 40-50 PSI at the gun. PPG BASECOAT/CLEARCOAT SYSTEMS PREPARATION 1. Solvent wipe with SX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron basecoat color (DBU), with the recommended reducer for the temperature, per label instructions. 2. Mix and apply clearcoat material DBU-88 or DCU-2001, with DX-369 Flexative, per label instructions. SHERWIN-WILLIAMS PRODUCTS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6029 Ultrabase 7 Basecoat/Clearcoat or Ultra One Stage Acrylic Urethane Enamel PREPARATION 1. Wash the material with a mild detergent and wipe dry. 2. Solvent wash with R7 K 156 and wipe dry. 3. Clean with a tack cloth. 4. Apply desired system with correct amount of Multi-flex, V6 V 299. TOPCOATING Prepare topcoating as follows: ^ S-W Ultra One Stage: (Mono-coat) 4 Parts Color 3 Parts SSR 650 Reducer 1 Part V6 V 440 or SSH 520 2 Parts V6 V 299 ^ S-W UB7 Basecoat: 8 Parts Basecoat Color 8 Parts Stabilizer 1 Part V6 V 299 ^ S-W UB7 Clearcoat: 4 Parts T1 C 650 Clearcoat 2 Parts T1 C 650 Reducer 1 Part CCH 690 1 Part V6 V 299 ^ S-W Ultra One Stage: (Mono-coat) Apply 2-3 medium wet coats at 50 PSI ^ UB7 Basecoat: Apply 2-3 medium coats at 45 PSI ^ UB7 Clearcoat: Apply 2-3 medium coats at 50 PSI DUPONT PRODUCTS DUPONT CRONAR POLYOXITHANE MONOCOAT SYSTEM PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING 1. Add 8 parts of Cronar single stage enamel. 2. Add 1 part Cronar initiator 9404S. 3. Add two parts of (9475S, 9485S, or 9495S,) depending on shop temperature. 4. Add 2 parts flex-additive 9250S. 5. Mix thoroughly. 6. Spray at 45-55 PSI at the gun, 2-3 medium wet coats or until hiding. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6030 7. If a clear coat is applied, use 9500S. DUPONT CENTARI MONO-COAT ENAMEL SYSTEMS PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING (Follow Manufacturer's Recommendation) 1. Add 8 parts of Centari enamel color and 1 part 793S hardener. 2. Add 4 parts of (8022S, 8093S, or 8096S) reducer, depending on shop temperature. 3. Add 355S flex additive per label instructions. 4. Mix thoroughly. 5. Spray 2-3 wet coats, with 5 minutes flash time, at 50-65 PSI. BASF PRODUCTS The following procedure is applicable to 4 paint systems in the BASF paint line. Read individual "system" instructions carefully. PREPARATION 1. Solvent wipe the molding with RM Pre-klean-o 900. 2. Sand with 400 grit sand paper and rinse with 901 pre-paint cleaner. TOPCOATING BASECOAT ^ "Glasurit" 54-line color 2 vol. parts ^ 54-line reducer 1 vol. part ^ "Diamont" basecoat color 2 vol. parts ^ B R Diamont reducer 2 vol. parts ^ "Miracryl" basecoat color 2 vol. parts ^ BCR reducer 2 vol. parts ^ "Supreme Gold" basecoat color 2 vol. parts ^ LBR reducer 2 vol. parts Apply basecoat color until hiding is achieved. Allow 3-5 minutes flash time between coats. NOTE: USE APPROPRIATE REDUCER FOR SHOP CONDITIONS. ALLOW 15 MINUTES FLASH-OFF BEFORE SPRAYING CLEARCOAT. TOPCOATING Apply clearcoat per manufacturer's label instructions: CLEARCOAT REDUCTIONS ^ DC-88 Diamont Clear 4 Vol. Parts ^ DH-44 Diamont Hardener 1 Vol. Part ^ MC-1000 Clear 4 Vol. Parts ^ 894 Hardener 1 Vol. Part ^ LC-1300 Supreme Gold Clear 4 Vol. Parts ^ LH-1301 Hardener 1 Vol. Part Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6031 ^ 92354 Glasurit Clear 100 Parts ^ 521-111 Elastifier 20 Parts ^ 929-29 Hardener 60 Parts Apply 2 wet coats with 5 to 10 minutes flash time between coats. Overnight dry or force dry at 140~F for 30 minutes. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. (E) Lower Body-Side Stone Chip Protection Program Ford Motor Company has recently initiated a program to provide improved stone-chip protection on some vehicles and to increase the corrosion protection on cars and trucks. Some customers are unaware of body side anti-stone chip protection which appears as wavy orange peel texture on the lower body areas. Ford is increasing the use of PVC (poly vinyl chloride) material which is applied in a thicker coating on the lower body-side. This material has been in use on vehicles destined for the Canadian market for many years. This PVC material is now applied at the following plants on ALL vehicles. ^ Edison - Ranger ^ Hermosillo - Escort/Tracer ^ Louisville - Ranger and Explorer ^ Ohio Truck - Econoline ^ Wayne - Escort/Tracer This process is also planned for Kansas City, Oakville, Twin Cities and Wixom. This material can be identified by the "orange peel" appearance and a visible "break-line" between protected and unprotected areas in the lower body areas. CAUTION: THIS PROTECTION MUST NOT BE REMOVED IF VEHICLE IS EXPECTED TO MAINTAIN THE CORROSION PROTECTION. Some customers have expressed concerns due to the appearance of the treated areas. These customers did not know about the extra protection this material provides their vehicle. Once explained, customers were pleased with the added protection and accepted the orange peel finish. NOTE: DEALERS SHOULD ADVISE THEIR SALES PEOPLE, SERVICE PEOPLE, AND CUSTOMERS, OF THE REASONS AND BENEFITS OF THIS PROTECTION. CANADIAN DEALERS STRESS THIS AS A SELLING POINT WITH THEIR SALES PEOPLE. IT IS CONSIDERED A COMPETITIVE ADVANTAGE. (F) Surface Defect Removal Without Repainting Exterior paint surface damage or imperfections, where the primer coat does not show through, should be restored without repainting. The restoration of gloss and luster, after the condition has been repaired, is possible with new techniques and improved materials. The following procedure is applicable to surface conditions such as dirt particles, orange peel, runs, sags, industrial fallout stains, swirl marks, light scratches and other minor surface imperfections. For dirt particles or scratches in several localized areas, the entire panel should be refinished to maintain a uniform appearance. PREPARATION To repair the affected surface it must be clean and dry. Mask off adjacent panels, mouldings, stripe and character lines as required. CAUTION: EYE PROTECTION, AND FACE MASK SHOULD BE WORN. RINGS, BRACELETS, WATCHES AND BELT BUCKLES MUST BE REMOVED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. SERVICE PROCEDURE 1. Remove sanding marks with rubbing compound. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6032 2. Swirl marks, evident after buffing, are removed by polishing. 3. Remove light scratches and small dirt particles with a power buffer and medium buffing compound followed with polishing. 4. Remove deeper scratches and heavy dirt particles or orange peel, by wet sanding. 5. Buff with compound to remove the sanding marks and then polish to remove the swirl marks from the buffing operation. NOTE: PERFORM A TRIAL REPAIR WITH A SMALL AREA. FIRST, TRY POLISHING; IF THIS IS NOT SUCCESSFUL, TRY BUFFING AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE MOST EFFECTIVE TECHNIQUE ON REMAINDER OF AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. POLISHING - VERY MINOR SCRATCHES OR SWIRL MARKS AND/OR RESTORING A DULL FINISH 1. Apply a small amount of Meguiar's Mirror Glaze, or equivalent, to the affected panel (or pad). 2. Use a suitable electric or air powered polish/buffing wheel (1750 max. RPM) and a Meguiar's Finesse Polishing Pad, or equivalent, to polish the affected area until all swirl marks are gone and desired luster is obtained. 3. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is sufficient. CAUTION: DO NOT MIX PRODUCTS! USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is 1200-1750 RPM. COMPOUNDING - LIGHT SCRATCHES, SMALL DIRT PARTICLES, MINOR GRIND MARKS, AND SANDING MARKS 1. Apply Meguiar's Rubbing Compound (medium) or equivalent to the panel with a clean compound pad on the wheel. 2. Spread the compound evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add compound as required. 5. When buffing is complete, polish the panel as described previously. Twisted wool cutting pads are the most effective compounding pads to use with Glaze Machine Cleaner for removing paint defects and heavy oxidation. Following the use of a wool compounding pad, it may be necessary to polish the finish with No. 2 Mirror Glaze Hi-Tech Cleaner using a Mirror Glaze Finesse Polishing Pad to remove the deep swirl marks. GENERAL TECHNIQUES AND HINTS ^ "Foam" buffing pads create added gloss and depth of color on all types of paint finishes without creating buffer swirl marks. ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action. ^ Always apply cleaner to buffing pad, not directly on the oxidized paint surface. Dry paint absorbs material into pores upon contact. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat. ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency. ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn through. It is best to buff up to them from each side. ^ Always use a "wet buff" technique on a basecoat/clearcoat finish. This is a precaution against buffer swirls. Stop buffing just after the product begins to break down and before an overall dry, glossy finish appears. After "wet buffing", use a towel to wipe off the excess material. ^ Always use a "dry buff" technique on light colored, conventional paint finishes. Continue buffing until the material breaks down and only a slight film remains for final wipe off. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6033 ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish. Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILD-UP AND POSSIBLE BURN THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. NOTE: HEAT BUILD-UP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING ... AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED, THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, GROUND THE SURFACE BEING BUFFED TO METAL. WET SANDING Paint defects and sanding marks must be completely removed without using compounds and abrasive cleaners that scar the finish. Mirror Glaze Hi-Tech Finesse Sanding Papers provide uniformity in grit particle size and distribution. Using these precision made sanding papers, water sanding marks can be removed with Meguiar's cleaner and finesse polishing pads. ^ Typical paint defects that are repaired with this system include: dirt-in paint, solvent pop, cratering, orange peel, drips, scratches, water spots, and acid rain. ^ Always use the least abrasive (highest grit) sanding products possible to do this job. The following wet sanding procedure utilizes light grit sand paper or sanding blocks for removal of surface damage. These materials cut quickly leaving a uniform finish requiring a minimum of buffing to restore gloss. PROCEDURE 1. Squeeze water to flush the area to be sanded. Continue to flush water to the surface during sanding for maximum lubrication. 2. Use small circular motions to contain the abrasion to the immediate area of the defect. Keep the blocks in water when not in use. 3. If the sanding block is cutting too slow, switch to a lower grade block and resume sanding. When 90% of the defect is removed, switch to a 2000 grade Finesse Sanding Paper or Sanding Block to finish smoothing and prepare the surface for buffing. 4. Finesse Sanding Blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using Finesse Sanding Papers, wrap the paper tightly around a E-7200 Backing Pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. NOTE: ALWAYS SAND IN ONE DIRECTION AND KEEP YOUR STROKES STRAIGHT. 7. Always finish sanding with 2000 Grit Finesse Sanding Paper. This eliminates the need for compounding. 8. Buff out sanding marks by applying Meguiar's Cleaner with a Finesse "Foam" Polishing Pad. Follow with a Mirror Glaze Polish for swirl-free gloss. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS RUNS AND SAGS REMOVAL This procedure consists of shaving the run or sag flush with a commercial single edge razor blade, shaving file or sanding with a hard block and then compounding. NOTE: IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT PANEL FINISH. MEGUIAR'S PRODUCTS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6034 PART NUMBER GRADE PART NAME S-1005 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Half Sheets S-1205 1200 S-1505 1600 S-2005 2000 S-1000 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Full Sheets 8-1200 1200 8-1500 1500 S-2000 2000 E-7200 - Mirror Glaze Hi-Tech Finesse Backing Pad E-2000 - Mirror Glaze Hi-Tech Tach Sponge K-400 400 Mirror Glaze Hi-Tech Finesse Sanding Blocks K-1000 1000 K-1500 1500 K-2000 2000 K-3000 3000 Other Applicable Articles: 82-3-3 (G) Color Compatible Spray Primer Chart Ford has released color compatible spray primers for exterior and some interior surfaces. Colored sprayed primers are being used by our "Best-in-Class" competition and are now being implemented at Ford in order to improve process capability and to help in minimizing unsightly paint chipping from stone abrasion. Color keyed (matched) spray primer for exterior body colors is being used in an effort to help in the elimination of unsightly paint chipping from stone abrasion. As with "Best-In-Class" competition, the engine compartment will be left with color compatible primer only and not be topcoated as per past practice. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6035 Figure 5 When any paint repair is required, remember that the vehicle may have a colored primer. Refer to the Spray Primer Chart, Figure 5. This information may be of help in correction of exterior paint color match concerns. (H) Paint Repair For Tinted Clear Coat Ford introduced (Early Spring, 1991) a new paint color using a tinted clearcoat. The first color to use this new system is Rio Red. If a paint repair is necessary, refer to the following procedure for repair instructions. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6036 BACKGROUND The Probe production paint system for Rio Red includes a Medium Green E-Coat primer, a Light Gray spray primer, bright Rio Red (E4) basecoat and a slightly Red tinted clearcoat topcoat. NOTE: BEFORE ANY REPAIRS ARE BEGUN, IT IS CRITICAL THAT PRIMER, RED BASECOAT AND TINTED CLEARCOAT BE SPRAYED ON A TEST PANEL. THE COLOR MATCH IN EACH STEP IS VERY IMPORTANT FOR A SUCCESSFUL REPAIR. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SMALL SPOT REPAIR PROCEDURE 1 Wash the vehicle with detergent soap and water. 2 Wipe the vehicle down with wax and grease remover. 3. Sand the spot using 400 grit paper. Do not sand through the E-coat. 4. Wipe the sanded surface again with wax and grease remover/pre-cleaner. ^ BASF Product # 90 Pre-Kleano ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mix and apply tintable (Light Gray) self-etching or epoxy primer per manufacturer's label instructions. NOTE: COLOR MATCH OF PRIME COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. ^ BASF Product # DE 17 ^ PPG Product # DP 40 ^ S-W Product # E2-G973 ^ DuPont Product # 615S ^ Sikkens Product # 1016 6. Mix and apply bright Rio Red base coat material per manufacturer's label instructions. NOTE: COLOR MATCH OF BASE CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. 7. Mix and apply red tinted clearcoat material per manufacturer's label instructions. NOTE: COLOR MATCH OF TINTED CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. FULL PANEL REPAIR PROCEDURE 1. Wash the vehicle with detergent soap and water. 2. Wipe the vehicle down with wax and grease remover. 3. Sand the complete panel and feather edge into the next panel using 400 grit paper. Do not sand through the E-Coat primer. 4. Wipe the sanded surface with wax and grease remover. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6037 5. Mix and apply tintable (light gray) primer per manufacturer's label instructions. 6. Mix and apply Rio Red basecoat per manufacturer's label instructions. 7. Mix and apply Red tinted clearcoat per manufacturer's label instructions. 8. Mix and apply one coat of non-tinted clearcoat per manufacturer's label instructions. NOTE: COLOR MATCH OF EACH COAT ARE KEY TO COLOR MATCH OF FINISH REPAIR. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C's) OR EXCESS MATERIALS. (I) Paintable Plastics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6038 Figure 6 The Paintable Plastics Chart, Figure 6, is a summary of widely used plastics in our industry. The standard symbol should be located on the part for ease of material identification. If painting or repair of these plastics is necessary, the following chart identifies those materials which can be painted. Refer to paint manufacturer for specific paint material recommendations. NOTE: MATERIALS MAY REQUIRE PRIME COAT SEE "YES", UNDER "CAN BE PAINTED" COLUMN. (J) 1992 Paint Color Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 6039 Figure 7 The 1992 Paint Color Codes are listed in Figure 7. NOTE: REFER TO THE SERVICE LABOR TIME STANDARDS MANUAL AND THE SPECIFIC PROCEDURE WITHIN THIS BULLETIN FOR REIMBURSEMENT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OASIS CODES: 106000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure Technical Service Bulletin # 90153 Date: 900719 Lower Body Stone Protection - Repair Procedure PAINT - LOWER BODY STONE PROTECTION REPAIR TIPS Article No. 90-15-3 FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA, PROBE LINCOLN-MERCURY: 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A service repair procedure has been developed to restore damaged factory-applied lower body stone protection vinyl material. ACTION: If service is required, use the following procedure to restore damaged lower body stone protected areas. This abrasion resistant coating material (D9AZ-19515-A) is primarily for repair of factory-applied protective coatings. However, this material may also be installed on previously unprotected vehicles. If the vehicle has body damage in the area of the factory-applied coating, body damage must be repaired before repairing the protective coating. WARNING: WHENEVER USING PAINT, SOLVENT, REFINISHING OR RECONDITIONING MATERIALS, WEAR A NOSE OR FACE MASK, PLUS HAVE ADEQUATE VENTILATION IN THE WORK AREA. Large Repair Areas A large repair area, resulting from peeling or damage, will require removal of the factory-applied vinyl coating. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR OR QUARTER PANEL REPLACEMENT IS REQUIRED, (OR IN AN INITIAL INSTALLATION), SKIP STEPS # 1 - 3. 1. Use a heat gun or lamp to soften the vinyl coating until it is pliable. 2. Scrape off the softened vinyl with a putty knife or similar tool. If necessary, sand off any hard-to-remove vinyl coating using an orbital disc sander (# 80 Disc). NOTE: THE REPAIR MATERIAL, ABRASION RESISTANT COATING (D9AZ-19515-A), IS NOT SUITABLE FOR "SPOT" REPAIRS. THE OLD COATING MUST BE REMOVED COMPLETELY FROM EACH DAMAGED PANEL. 3. Make the necessary repairs to the sheet metal. Coating Preparation and Applications: The abrasion resistant coating is available in quart cans. About two quarts will be required for an initial installation on a passenger car similar to a factory-applied system. Slightly more will be required for a larger vehicle such as an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020") will require at least three or possibly four applications of coating material, with flash off time allowed between coats. As with painting, spray coat the complete lower panel. The adherence of this coating to properly prepared sheet metal is excellent and it is not necessary to prime the repaired sheet metal. However, adhesion will be adversely affected unless the sheet metal (either repaired or new) is prepared in accordance with the following procedure. Coating Preparation - Masking Car 1. Install covers over the wheels. 2. Determine the area to be coated. ^ If the vehicle has lower body side mouldings (12-14" above the "turn under" of the rocker Panel), the moulding can serve as the upper margin of the area to be coated. ^ If the vehicle does not have suitable mouldings, a sculpture or break line in the sheet metal can be used. ^ The method used in masking off the upper coating margin line will depend on the presence or absence of mouldings in this area. VEHICLES WITH SIDE MOULDINGS 3. Position the masking tape so that the moulding lower side is covered down to, but not on the sheet metal. VEHICLES WITHOUT SIDE MOULDINGS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure > Page 6044 4. If the contour of the body side has a break line, or if an arbitrary line is chosen, mask off the upper coating margin using Scotch "Fine Line" tape. This is available nationally from 3M Company Distributors. a. Apply the normal masking tape and paper protection for the vehicle body side first. Position them about a 1/4" above the margin line. b. Apply the "Fine Line" tape over the regular masking tape with the lower edge at the upper coating margin line. c. Extend this "Fine Line" tape into the wheel opening, in absence of wheel opening mouldings, to allow the flange to be coated. d. Since the protective coating does not adhere well to flexible plastic stone shields, mask off the front of the plastic rear stone shield, if exposed. NOTE: IT IS NOT NECESSARY TO MASK OFF THE BODY DOOR OPENINGS IN THE COATING AREA BECAUSE THEY WILL BE UNIFORMLY COATED WHERE THE DOOR MARGINS ALLOW THE COATING TO ENTER. HOWEVER, THESE DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. Coating Preparation - Sheet Metal REPAIRED SHEET METAL 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover and allow to flash off. 2. Scuff sand (# 180 Grit Paper) the glossy surface of the painted areas to be coated. 3. Remove sanding dust using a lint-free tack cloth and compressed air. NEW SHEET METAL 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover and allow to flash off. 2. Scuff sand (# 180 Grit Paper) the prime paint in the area to be coated. 3. Remove sanding dust using a lint-free tack cloth and compressed air. INITIAL INSTALLATION 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover. 2. Sand the glossy surface of the paint in the coating area. (A D/A sander, 220/240 Grit Disc does a good fast job.) CAUTION: DO NOT SAND THROUGH THE COLOR COAT INTO THE PRIMER. 3. Remove sanding dust using a lint-free tack cloth and compressed air. Coating Application Coating applications must be applied with care. ^ The coating must be applied with commercial equipment by an experienced automotive painter. ^ The coating must be thoroughly agitated and used without thinning. ^ Since the material is reasonably heavy-bodied, a pressure cup equipped spray gun is recommended. ^ Satisfactory coating appearance (orange peel) will result with gun pressure of approximately 30 P.S.I. and cup pressures of approximately 15 P.S.I. Spray Procedure Since the lower exposed painted fender, rocker and quarter panel down flanges are to be coated, the vehicle should be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote, two-quart capacity pressure cup makes a much more efficient tool because the spray gun can be used closer to the floor. The spray gun, fluid hose and cup must be cleaned immediately after use. While lacquer thinner may be used when the suggested clean up material is unavailable, the Ford Vinyl Paint Precleaner (VC-542-A) is quicker and much more efficient. With the spray gun at 30 P.S.I. and pressure feed cup at 15 P.S.I. proceed as follows: Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure > Page 6045 1. Apply a wet, sag-free coat. Allow 3 to 5 minutes flash off. 2. Apply a second wet, sag-free coat. Allow 3 to 5 minutes flash off. 3. Apply a third wet, sag-free coat. Allow 3 to 5 minutes flash off. 4. Apply a final wet, sag-free coat. Allow 3 to 5 minutes flash off. Pull off the "Fine Line" tape, exposing the raw upper edge of the coating. 5. Immediately clean the spray equipment using Ford Vinyl Paint Precleaner (VC-542-A) or equivalent. 6. Air drying time depends on the refinishing materials that are used. ^ If you refinish with acrylic lacquer, allow one hour for drying (at 70~F). ^ If you refinish with acrylic enamel, allow two hours for drying (at 70~F). Color Coat In order to paint the entire coated area as well as the upper raw edge, mask off the upper margin line using the "Fine Line" tape. Position the tape 1/16" above the coating edge. The protective coating area can now be finish painted. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. Suggested Equipment ^ DeVilbiss - Spray Gun - Model JGA-502-704-FX or equivalent ^ DeVilbiss - Remote Pressure Cup - Model KB-520 (2 Quarts), Model KB-521 (1 Quart) or equivalent ^ Binks - Spray Gun - Model 62 (# 63 Air Cap, # SS Fluid Tip, # 363 AN Needle) ^ Binks - Attached Pressure Cup - Model 80 (1 Quart, with Air Adjusting Gage) or equivalent. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100, 1800 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6050 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6051 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6052 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 6053 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 85113 > Jun > 85 > Paint - Revised Prices Paint: Technical Service Bulletins Paint - Revised Prices Article No. 85-11-3 REVISED PAINT PRICES FORD 1985 ALL MODELS LINCOLN-MERCURY 1985 ALL MODELS LIGHT TRUCK 1985 ALL MODELS MEDIUM/HEAVY TRUCK 1985 ALL MODELS The following revised paint prices supercede those currently published on page P-4 of the Service Labor Time Standards Manuals. A ............... $ 9.10 G .............$ 14.30 B ................ 9.65 H ............... 16.15 C ............... 10.70 J ............... 17.40 D................ 11.15 K............... 19.50 E ............... 11.95 L ............... 20.50 F ............... 13.90 M............... 35.30 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 84171 > Aug > 84 > Fleet Colors - Revised Paint Code Numbers Technical Service Bulletin # 84171 Date: 840814 Fleet Colors - Revised Paint Code Numbers Article No. 84-17-1 PAINT - CODES - REVISED 1985 FLEET COLOR PAINT CODE NUMBERS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCKS 1985 ALL The following charts list stock numbers for 1985 fleet colors. Other colors used have been released for 1985 service and are referenced in 1985 aftermarket color charts. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Service Refinish Codes FOR THE NEW "330" SPECIAL PAINT SELECTOR COLORS This is a reproduction of the Technical Service Information Bulletin dated 1/28/72. REVISED FLEET COLOR REPAIR PAINT CODE NUMBERS Air dry enamel or lacquer repair paints are available in the following revised list of special order colors. They can be obtained from suppliers of refinishing materials. The Ford Motor Company code number designation and its corresponding vendor code number is given for each color. The color charts corresponding to these codes are in the revised Special Order Paint Selector Book that will be issued to each Ford and Lincoln-Mercury Dealership in mid-February. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 84171 > Aug > 84 > Fleet Colors - Revised Paint Code Numbers > Page 6062 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 84171 > Aug > 84 > Fleet Colors - Revised Paint Code Numbers > Page 6063 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 84171 > Aug > 84 > Fleet Colors - Revised Paint Code Numbers > Page 6064 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 84171 > Aug > 84 > Fleet Colors - Revised Paint Code Numbers > Page 6065 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 84171 > Aug > 84 > Fleet Colors - Revised Paint Code Numbers > Page 6066 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > 84171 > Aug > 84 > Fleet Colors - Revised Paint Code Numbers > Page 6067 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6068 Technical Service Bulletin # 91181 Date: 910905 Exterior Paint - Comprehensive Repair Procedures Article No. 91-18-1 09/05/91 PAINT-EXTERIOR-COMPREHENSIVE REPAIR PROCEDURES FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-92 TAURUS 1988-92 FESTIVA 1989-92 PROBE LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1988-92 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-92 AEROSTAR 1991 EXPLORER ISSUE: A comprehensive paint repair procedure TSB has been developed for service use. It includes the following paint repair topics: Section (A) has been superseded by TSB # 9264, dated 3/92. (B) Exterior Color Peeling From Ultra Violet Light (C) Lower Body Stone Protection Repair Tips (D) Procedures For PVC Body Side Moldings (E) Lower Body-Side Stone Chip Protection Program (F) Surface Defect Removal Without Repainting (G) 1991 Color Matched/Compatible Spray Primer Chart (H) Repair For Tinted Clearcoat (I) Frequently Used And Paintable Plastics (J) 1992 Paint Codes ACTION: If paint repair is required, refer to the following procedures for paint restoration. Section A Has Been Superseded By TSB # 9264, Dated 3/92. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS PROCEDURE # 2 FINISH KARE FORMULA # 1119 AND # 883 (Buffered solution not as harsh on aluminum parts) WARNING: FOR YOUR SAFETY, USE RUBBER GLOVES, GOGGLES AND PROTECTIVE CLOTHING WHEN HANDLING THESE PRODUCTS. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6069 1. Apply hot diluted solution with soft mitt. 2. Agitate to create suds. Suds hold the acid solution in suspension and to the surface creating greater and extended activity. 3. Allow 3 to 5 minutes dwell time. 4. Rinse with COLD WATER. 5. Apply # 883 per label instructions. LIQUID NEUTRALIZER CONCENTRATE 1. Using a mitt, thoroughly go over the entire surface with the diluted solution (50-1) of water and # 118 Liquid Neutralizer Concentrate. Then wipe dry. 2. If the iron particles are not totally removed after 2 washings, use one or both of the following service actions. a. Sand with micro fine sandpaper (1500 Grid or greater) in localized areas. b. Buff with very light compound and polish with wax in localized areas. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'S) OR EXCESS MATERIALS. (B) Paint Exterior Color Peeling From Ultra Violet Light Paint may be damaged because of ultra violet light absorption through the color coat. This damage will cause the top coat to peel to the E-coat primer. If service is required, use the following procedure to correct the concerns. NOTE: READ THE ENTIRE SERVICE PROCEDURE BEFORE STARTING REPAIRS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT. 1. Wash the vehicle with soap and water. 2. Verify topcoat adhesion by applying a 2 inch wide masking tape strip on all body panels above and below the beltline on each panel. a. Pull the tape up quickly. b. Inspect the adhesive side of the tape for paint removal. NOTE: IF PAINT WAS REMOVED DURING THE TAPE TEST, THE ENTIRE PANEL SHOULD BE STRIPPED AND REFINISHED AS NECESSARY. 3. Remove all trim (mouldings, name plates, striping, etc.) from the areas which will be repainted. NOTE: ALL REQUIRED REPLACEMENT MOULDINGS AND STRIPES SHOULD BE ORDERED AND RECEIVED PRIOR TO REPAIRING THE CUSTOMER'S VEHICLE. 4. Wipe the entire vehicle with wax and grease remover. ^ BASF Product # 900 Prekleano ^ PPG Product # DX300 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mask off all areas on the vehicle which are not going to be painted or will be affected by overspray (engine compartment, wheels, etc.). Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6070 6. Remove the paint to bare metal from all the areas of the vehicle which are going to be repainted. Use one of the following methods. SAND THE AFFECTED AREAS TO BARE METAL USING 40 GRIT 3M GREEN CORPS SANDING DISCS OR EQUIVALENT AND A SOFT PAD ON A 1700 RPM POLISHER. KEEP THE POLISHER MOVING TO AVOID DEVELOPING HOT SPOTS ON THE METAL. NOTE: CHEMICAL STRIPPING IS NOT RECOMMENDED. NOTE: IF AVAILABLE, PAINT MAY BE REMOVED USING A PLASTIC MEDIA BLAST SYSTEM. IF THIS PROCESS IS USED, EXTRA CARE MUST BE TAKEN DURING THE MASKING PROCESS TO PREVENT DAMAGE TO GLASS, MOULDING, ETC. 7. Blow off the entire vehicle to remove loose dust and debris. NOTE: IF RUST IS PRESENT, USE APPROPRIATE METAL CLEANER AND CONDITIONER (PHOSPHATE COATING) OVER BARE METAL AREAS. 8. Wipe all affected areas with a fast dry enamel reducer solvent, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. NOTE: THIS STEP WILL REDUCE THE POSSIBILITY OF FLASH RUST. ^ BASF Product # BR 50 ^ PPG Product # DX 300 ^ S-W Product # R7 K156 ^ DuPont Product # 3812 S ^ Sikkens Product # 123 FAST 9. Apply two medium wet coats (1.0 mil total) of self-etching, anti-corrosion primer using the manufacturer's recommendations and flash times. ^ BASF Product # DE-17 ^ PPG Product # DP EPOXY PRIMER ^ S-W Product # E2-6980 ^ DuPont Product # VARIPRIME ^ Sikkens Product # WASH FILLER 580 10. Apply three medium wet coats (2.0 mils total) of acrylic urethane primer surfacer following the manufacturer's recommended procedures. ^ BASF Product # DP-20 PRIMER/SUFACER ^ PPG Product # K-36 ^ S-W Product # P6-M49 OR P6-A48 ^ DuPont Product # URO PRIMERFILLER ^ Sikkens Product # AUTOCRYL 3+1 FILLER 11. Sand the vehicle using one of the following methods: ^ Wet-sand by hand using 400 grit or finer sandpaper. ^ Dry-sand by hand using 320 grit or finer sandpaper. 12. Blow the entire vehicle off to remove loose dust and debris. 13. Demask (remove all paper and tape) as necessary to remove the primer and dirt buildup on the paper and tape. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6071 14. Wipe the entire vehicle with wax and grease remover, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. ^ BASF Product # 901 PRE-PAINT CLEANER ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3812 S ^ Sikkens Product # M 600 15. Mask all areas on the vehicle which are not to be painted or will be affected by paint overspray (engine compartment, wheels, etc.). NOTE: APPLY BASECOAT/CLEAR COAT ONLY TO SURFACES WHICH ORIGINALLY HAD BASECOAT/CLEAR COAT 16. Apply three medium wet coats (enough material to hide primer) of acrylic enamel base coat or acrylic urethane monocoat following the manufacturer's recommended procedure. ^ BASF Product # DIAMONT BASECOAT/Solo ^ PPG Product # DELTRON BASECOAT DBC/Deltron ^ S-W Product # ULTRA BASE/Ultra One Stage ^ DuPont Product # CHROMABASE/Cronar ^ Sikkens Product # AUTO BASE/Autocryl 17. Apply two medium wet coats of 2K acrylic urethane enamel clear coat, following manufacturer's recommended procedure. ^ BASF Product # DIAMONT CLEAR 88/89 ^ PPG Product # CONCEPT 2001 DCU ^ S-W Product # CC-650 OR CC-640 ^ DuPont Product # 1080 S URO CLEAR ^ Sikkens Product # AUTO CLEAR 18. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray. 19. Polish the vehicle as necessary to remove any defects in the paint which may create a customer concern. CAUTION: USE LOW SPEED (1700 RPM MAXIMUM) POLISHER. 20. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior to repainting. 21. Clean the exterior and interior of the vehicle thoroughly, including air ducts and other areas which are prone to accumulating dust. This step is essential to ensure customer satisfaction. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6072 Figure 1 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6073 Figure 2 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6074 Figure 3 STRIP AND REFINISH CLAIMING METHODOLOGY The claiming instructions shown in Figure 1 are applicable to the repair of the EXTERIOR COLOR PEELING FROM ULTRA VIOLET LIGHT concern covered in this TSB only. See the SAMPLE CLAIMS, Figures 2 and 3, for examples. (C) Lower Body Stone Protection Repair Tips Ford has introduced a vinyl anti-stone abrasion material for the lower exterior body surfaces of selected passenger vehicles and light trucks. The anti-stone abrasion material is applied to the lower fenders, rocker panels, lower doors, quarter panel dogleg, and lower rear of quarter panel behind the wheel. The anti-stone abrasion material will usually end at a body character line. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6075 While primarily for servicing of factory-applied protective coating, the following provides installation information. If the vehicle has experienced body damage in the factory-applied material protective area, the sheet metal damage must be serviced prior to the application of the new protective coating. SMALL AREAS - MINOR DEFECTS (VEHICLES WITH FACTORY SPRAYED-ON VINYL) A small dent in the sheet metal that did not mar the vinyl surface, can possibly be corrected with proper bumping tools without damage to the vinyl coating. However, noticeable scratches or gouges (not over 1/2 inch in diameter) or dings and dents that when "ironed out" show vinyl damage, can be satisfactorily serviced with the following procedure: 1. Solvent-wipe the damaged area with "Silicone and Wax Remover." 2. Using a heat gun or lamp, soften the vinyl coating of the damaged area until it can be scraped off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The spray-on vinyl protective coatings may not be suitable for "spot" application. See Manufacturer's label for instructions.) 3. Perform necessary servicing to correct the sheet metal damage. 4. Using white bodyfiller, fill the damaged area. Follow the instructions on the label and blend the bodyfiller with the surrounding sheet metal. 5. Allow the bodyfiller to completely cure and then carefully sand the area smooth, removing any high spots. 6. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. LARGE DAMAGED AREAS - VEHICLE WITH FACTORY SPRAYED ON VINYL Peeling or damage over a large area will necessitate removal of the factory sprayed-on vinyl coating. The following procedure is suggested. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR, OR QUARTER PANEL REPLACEMENT IS REQUIRED (OR IN AN INITIAL INSTALLATION), DISREGARD STEPS NO. 1 AND NO. 2. 1. Using a heat gun or lamp, soften the vinyl coating until it is pliable. Scrape coating off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The vinyl material, abrasion resistant coating may not be suitable for "spot" applications. See manufacturer's label for instructions.) 2. Perform necessary servicing to correct the sheet metal damage. 3. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. COATING APPLICATIONS Approximately two quarts will be required for an initial installation on a passenger car or F-Series. Slightly more will be required for an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020 inch) will require at least three, possibly four, applications of coating material, with "flash off" time between coats. Spray coat complete panels only. The coating must be applied with commercial equipment by an experienced automotive painter. The coating must be thoroughly agitated before application. The material is heavy bodied. A pressure cup spray gun or "Rocker Schutz Gun" is recommended. COATING PREPARATION - MASKING VEHICLE Install suitable covers over the wheels. NOTE: IF THE VEHICLE HAS LOWER BODY SIDE MOULDINGS (12-14 INCHES ABOVE THE "TURN UNDER" OF THE ROCKER PANEL), THE MOULDING CAN SERVE AS THE UPPER MARGIN OF THE AREA TO BE COATED. IF THE VEHICLE DOES NOT HAVE SUITABLE MOULDINGS, A SCULPTURE OR BREAK LINE IN THE SHEET METAL CAN BE UTILIZED. THIS LINE SHOULD BE SELECTED TO ENSURE ADEQUATE PROTECTION OF THE PAINTED SURFACES. VEHICLES WITH BODY SIDE MOULDINGS 1. Masking tape should be positioned so that the moulding lower edge is also covered. The adjoining sheet metal should be left uncovered too so anti-stone, abrasion vinyl can be applied. VEHICLES WITHOUT BODY SIDE MOULDINGS 2. If the contour of the body side has a break line, the upper coating margin must be masked off using 3M "Fine Line" Tape. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6076 a. The normal masking tape and paper protection for the body side should be applied first and positioned about a quarter inch above the margin line. b. The "Fine Line" tape should then be applied over the regular masking tape with the lower edge at the upper coating margin line. Extend this "Fine Line" tape into the wheel opening, in the absence of wheel opening mouldings, allowing the flange to be coated. c. The anti-stone abrasion coating does not adhere well to flexible plastic parts. If left exposed, they must be masked off. d. It is not necessary to mask off the body door openings in the coating area, as they will be uniformly coated where the door margins allow the coating to enter. NOTE: DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. COATING PREPARATION - SHEET METAL REPAIRED SHEETMETAL 1. Scuff sand (No. 180 Grit Paper) the glossy surface of the painted areas to be coated. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and lint-free tack cloth. NEW SHEET METAL 1. Sand off (No. 180 Grit Paper) the prime paint in the area to be coated. 2. Using a lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. NEW INSTALLATION 1. The glossy surface of the paint in the coating area must be sanded with a D/A sander. A 220/240 Grit Disc does a good, fast job. DO NOT sand through the primer. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. SPRAY PROCEDURE The lower exposed painted fender, rocker, and quarter panel down flanges should be protected. The vehicle must be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote two-quart capacity pressure cup makes a much more efficient tool, as the spray gun can be used closer to the floor. The spray gun, fluid hose and/or cup must be cleaned immediately after use. Refer to manufacturer's recommended cleaning procedure. Lacquer thinner can be used when the suggested clean up material is unavailable. WARNING: WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EOUIPMENT. 1. After preparing the new or damaged area(s), mix either Epoxy primer or Self-etch prime, per manufacturer's label instructions, and spray bare metal areas. ^ BASF DE15 or DE17 ^ Sikkens Metalflex CR Primer (1 coat only) ^ DuPont Variprime ^ S-W E2G 980 GBP Etching Filler ^ PPG DP 40 (only) 2. Apply 1-2 light prime coats over the bare metal areas. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6077 3. Allow the material to dry for 15-20 minutes before applying the anti-stone abrasion material. 4. Mix and apply anti-stone abrasion material per manufacturer's label instructions over the primed area. NOTE: AN ORANGE PEELED FINISH IS NORMAL WITH THESE PRODUCTS. ^ BASF Glassohyd 1109-1240/6 ^ Sikkens 0TO Bodycoat ^ DuPont 123-5 Vinyl ^ S-W G/W 295 Vinyl Gravel Guard ^ PPG DX 54 Roadguard ^ 3M Rocker Schutz NOTE: SOME ANTI-STONE ABRASION MATERIAL MAY REQUIRE A SLIGHTLY DIFFERENT MIXING PREPARATION, PROCEDURE AND APPLICATION. SOME ANTI-STONE ABRASION MATERIALS CAN NOT BE USED FOR SPOT REPAIR. CHECK WITH THE PAINT MANUFACTURER FOR RECOMMENDATIONS ABOUT THEIR PRODUCT. 5. Allow the stone abrasion material to dry. Heat can be used to accelerate the drying time. Check the manufacturer's instructions. COLOR COAT The complete coated area, as well as the upper raw edge, must be covered with color coat. Mask off the upper margin line using "Fine Line" tape positioned 1/16 inch above the coating edge. Using appropriate service paint and application procedures, the protective coating area can now be finish painted with monocoat or a basecoat/clearcoat urethane system. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Figure 4 Refer to the Lower Body Stone Protection Chart, Figure 4, for the material and labor hours involved. (D) Procedure For PVC Body Side Moldings If replacement of the body side molding is necessary, some dealer service kits will be supplied "paint to match." Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6078 The painting procedures in the following instructions (also included with the part) address materials from five (5) major aftermarket paint suppliers. Use the paint system materials you are the most familiar with. NOTE: CAREFULLY READ ALL LABEL WARNINGS BEFORE APPLYING THESE PRODUCTS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SIKKENS PRODUCTS PREPARATION 1. Degrease with M600 wax and grease remover. 2. Scuff with # 320 dry paper or Scotchbrite 7447 (red). 3. Repeat degreasing step. 4. Spray two medium coats of Plastoflex primer. Allow 5 to 10 minutes flash between coats. 5. Allow 20 minutes flash-off at 70~ F before topcoating. TOPCOATING 1. Mix Autocryl color with Elast-O-Actif 50:50 by volume. 2. Mix this material with 1.2.3 hardner and 1.2.3 reducer (use correct reducer for temperature) 100:50:30 by volume. 3. Apply three medium coats, allowing enough flash off to dry to a light touch. 4. Dry one hour at 140~F after 10 minutes flash off or dry 24 hours at 75~F. PPG PRODUCTS PPG MONO-COAT SYSTEMS 1. Solvent wipe with DX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron topcoat color with DX-369 Flexative per label instructions. 2. Use 40-50 PSI at the gun. PPG BASECOAT/CLEARCOAT SYSTEMS PREPARATION 1. Solvent wipe with SX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron basecoat color (DBU), with the recommended reducer for the temperature, per label instructions. 2. Mix and apply clearcoat material DBU-88 or DCU-2001, with DX-369 Flexative, per label instructions. SHERWIN-WILLIAMS PRODUCTS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6079 Ultrabase 7 Basecoat/Clearcoat or Ultra One Stage Acrylic Urethane Enamel PREPARATION 1. Wash the material with a mild detergent and wipe dry. 2. Solvent wash with R7 K 156 and wipe dry. 3. Clean with a tack cloth. 4. Apply desired system with correct amount of Multi-flex, V6 V 299. TOPCOATING Prepare topcoating as follows: ^ S-W Ultra One Stage: (Mono-coat) 4 Parts Color 3 Parts SSR 650 Reducer 1 Part V6 V 440 or SSH 520 2 Parts V6 V 299 ^ S-W UB7 Basecoat: 8 Parts Basecoat Color 8 Parts Stabilizer 1 Part V6 V 299 ^ S-W UB7 Clearcoat: 4 Parts T1 C 650 Clearcoat 2 Parts T1 C 650 Reducer 1 Part CCH 690 1 Part V6 V 299 ^ S-W Ultra One Stage: (Mono-coat) Apply 2-3 medium wet coats at 50 PSI ^ UB7 Basecoat: Apply 2-3 medium coats at 45 PSI ^ UB7 Clearcoat: Apply 2-3 medium coats at 50 PSI DUPONT PRODUCTS DUPONT CRONAR POLYOXITHANE MONOCOAT SYSTEM PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING 1. Add 8 parts of Cronar single stage enamel. 2. Add 1 part Cronar initiator 9404S. 3. Add two parts of (9475S, 9485S, or 9495S,) depending on shop temperature. 4. Add 2 parts flex-additive 9250S. 5. Mix thoroughly. 6. Spray at 45-55 PSI at the gun, 2-3 medium wet coats or until hiding. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6080 7. If a clear coat is applied, use 9500S. DUPONT CENTARI MONO-COAT ENAMEL SYSTEMS PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING (Follow Manufacturer's Recommendation) 1. Add 8 parts of Centari enamel color and 1 part 793S hardener. 2. Add 4 parts of (8022S, 8093S, or 8096S) reducer, depending on shop temperature. 3. Add 355S flex additive per label instructions. 4. Mix thoroughly. 5. Spray 2-3 wet coats, with 5 minutes flash time, at 50-65 PSI. BASF PRODUCTS The following procedure is applicable to 4 paint systems in the BASF paint line. Read individual "system" instructions carefully. PREPARATION 1. Solvent wipe the molding with RM Pre-klean-o 900. 2. Sand with 400 grit sand paper and rinse with 901 pre-paint cleaner. TOPCOATING BASECOAT ^ "Glasurit" 54-line color 2 vol. parts ^ 54-line reducer 1 vol. part ^ "Diamont" basecoat color 2 vol. parts ^ B R Diamont reducer 2 vol. parts ^ "Miracryl" basecoat color 2 vol. parts ^ BCR reducer 2 vol. parts ^ "Supreme Gold" basecoat color 2 vol. parts ^ LBR reducer 2 vol. parts Apply basecoat color until hiding is achieved. Allow 3-5 minutes flash time between coats. NOTE: USE APPROPRIATE REDUCER FOR SHOP CONDITIONS. ALLOW 15 MINUTES FLASH-OFF BEFORE SPRAYING CLEARCOAT. TOPCOATING Apply clearcoat per manufacturer's label instructions: CLEARCOAT REDUCTIONS ^ DC-88 Diamont Clear 4 Vol. Parts ^ DH-44 Diamont Hardener 1 Vol. Part ^ MC-1000 Clear 4 Vol. Parts ^ 894 Hardener 1 Vol. Part ^ LC-1300 Supreme Gold Clear 4 Vol. Parts ^ LH-1301 Hardener 1 Vol. Part Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6081 ^ 92354 Glasurit Clear 100 Parts ^ 521-111 Elastifier 20 Parts ^ 929-29 Hardener 60 Parts Apply 2 wet coats with 5 to 10 minutes flash time between coats. Overnight dry or force dry at 140~F for 30 minutes. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. (E) Lower Body-Side Stone Chip Protection Program Ford Motor Company has recently initiated a program to provide improved stone-chip protection on some vehicles and to increase the corrosion protection on cars and trucks. Some customers are unaware of body side anti-stone chip protection which appears as wavy orange peel texture on the lower body areas. Ford is increasing the use of PVC (poly vinyl chloride) material which is applied in a thicker coating on the lower body-side. This material has been in use on vehicles destined for the Canadian market for many years. This PVC material is now applied at the following plants on ALL vehicles. ^ Edison - Ranger ^ Hermosillo - Escort/Tracer ^ Louisville - Ranger and Explorer ^ Ohio Truck - Econoline ^ Wayne - Escort/Tracer This process is also planned for Kansas City, Oakville, Twin Cities and Wixom. This material can be identified by the "orange peel" appearance and a visible "break-line" between protected and unprotected areas in the lower body areas. CAUTION: THIS PROTECTION MUST NOT BE REMOVED IF VEHICLE IS EXPECTED TO MAINTAIN THE CORROSION PROTECTION. Some customers have expressed concerns due to the appearance of the treated areas. These customers did not know about the extra protection this material provides their vehicle. Once explained, customers were pleased with the added protection and accepted the orange peel finish. NOTE: DEALERS SHOULD ADVISE THEIR SALES PEOPLE, SERVICE PEOPLE, AND CUSTOMERS, OF THE REASONS AND BENEFITS OF THIS PROTECTION. CANADIAN DEALERS STRESS THIS AS A SELLING POINT WITH THEIR SALES PEOPLE. IT IS CONSIDERED A COMPETITIVE ADVANTAGE. (F) Surface Defect Removal Without Repainting Exterior paint surface damage or imperfections, where the primer coat does not show through, should be restored without repainting. The restoration of gloss and luster, after the condition has been repaired, is possible with new techniques and improved materials. The following procedure is applicable to surface conditions such as dirt particles, orange peel, runs, sags, industrial fallout stains, swirl marks, light scratches and other minor surface imperfections. For dirt particles or scratches in several localized areas, the entire panel should be refinished to maintain a uniform appearance. PREPARATION To repair the affected surface it must be clean and dry. Mask off adjacent panels, mouldings, stripe and character lines as required. CAUTION: EYE PROTECTION, AND FACE MASK SHOULD BE WORN. RINGS, BRACELETS, WATCHES AND BELT BUCKLES MUST BE REMOVED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. SERVICE PROCEDURE 1. Remove sanding marks with rubbing compound. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6082 2. Swirl marks, evident after buffing, are removed by polishing. 3. Remove light scratches and small dirt particles with a power buffer and medium buffing compound followed with polishing. 4. Remove deeper scratches and heavy dirt particles or orange peel, by wet sanding. 5. Buff with compound to remove the sanding marks and then polish to remove the swirl marks from the buffing operation. NOTE: PERFORM A TRIAL REPAIR WITH A SMALL AREA. FIRST, TRY POLISHING; IF THIS IS NOT SUCCESSFUL, TRY BUFFING AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE MOST EFFECTIVE TECHNIQUE ON REMAINDER OF AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. POLISHING - VERY MINOR SCRATCHES OR SWIRL MARKS AND/OR RESTORING A DULL FINISH 1. Apply a small amount of Meguiar's Mirror Glaze, or equivalent, to the affected panel (or pad). 2. Use a suitable electric or air powered polish/buffing wheel (1750 max. RPM) and a Meguiar's Finesse Polishing Pad, or equivalent, to polish the affected area until all swirl marks are gone and desired luster is obtained. 3. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is sufficient. CAUTION: DO NOT MIX PRODUCTS! USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is 1200-1750 RPM. COMPOUNDING - LIGHT SCRATCHES, SMALL DIRT PARTICLES, MINOR GRIND MARKS, AND SANDING MARKS 1. Apply Meguiar's Rubbing Compound (medium) or equivalent to the panel with a clean compound pad on the wheel. 2. Spread the compound evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add compound as required. 5. When buffing is complete, polish the panel as described previously. Twisted wool cutting pads are the most effective compounding pads to use with Glaze Machine Cleaner for removing paint defects and heavy oxidation. Following the use of a wool compounding pad, it may be necessary to polish the finish with No. 2 Mirror Glaze Hi-Tech Cleaner using a Mirror Glaze Finesse Polishing Pad to remove the deep swirl marks. GENERAL TECHNIQUES AND HINTS ^ "Foam" buffing pads create added gloss and depth of color on all types of paint finishes without creating buffer swirl marks. ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action. ^ Always apply cleaner to buffing pad, not directly on the oxidized paint surface. Dry paint absorbs material into pores upon contact. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat. ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency. ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn through. It is best to buff up to them from each side. ^ Always use a "wet buff" technique on a basecoat/clearcoat finish. This is a precaution against buffer swirls. Stop buffing just after the product begins to break down and before an overall dry, glossy finish appears. After "wet buffing", use a towel to wipe off the excess material. ^ Always use a "dry buff" technique on light colored, conventional paint finishes. Continue buffing until the material breaks down and only a slight film remains for final wipe off. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6083 ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish. Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILD-UP AND POSSIBLE BURN THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. NOTE: HEAT BUILD-UP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING ... AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED, THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, GROUND THE SURFACE BEING BUFFED TO METAL. WET SANDING Paint defects and sanding marks must be completely removed without using compounds and abrasive cleaners that scar the finish. Mirror Glaze Hi-Tech Finesse Sanding Papers provide uniformity in grit particle size and distribution. Using these precision made sanding papers, water sanding marks can be removed with Meguiar's cleaner and finesse polishing pads. ^ Typical paint defects that are repaired with this system include: dirt-in paint, solvent pop, cratering, orange peel, drips, scratches, water spots, and acid rain. ^ Always use the least abrasive (highest grit) sanding products possible to do this job. The following wet sanding procedure utilizes light grit sand paper or sanding blocks for removal of surface damage. These materials cut quickly leaving a uniform finish requiring a minimum of buffing to restore gloss. PROCEDURE 1. Squeeze water to flush the area to be sanded. Continue to flush water to the surface during sanding for maximum lubrication. 2. Use small circular motions to contain the abrasion to the immediate area of the defect. Keep the blocks in water when not in use. 3. If the sanding block is cutting too slow, switch to a lower grade block and resume sanding. When 90% of the defect is removed, switch to a 2000 grade Finesse Sanding Paper or Sanding Block to finish smoothing and prepare the surface for buffing. 4. Finesse Sanding Blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using Finesse Sanding Papers, wrap the paper tightly around a E-7200 Backing Pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. NOTE: ALWAYS SAND IN ONE DIRECTION AND KEEP YOUR STROKES STRAIGHT. 7. Always finish sanding with 2000 Grit Finesse Sanding Paper. This eliminates the need for compounding. 8. Buff out sanding marks by applying Meguiar's Cleaner with a Finesse "Foam" Polishing Pad. Follow with a Mirror Glaze Polish for swirl-free gloss. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS RUNS AND SAGS REMOVAL This procedure consists of shaving the run or sag flush with a commercial single edge razor blade, shaving file or sanding with a hard block and then compounding. NOTE: IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT PANEL FINISH. MEGUIAR'S PRODUCTS Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6084 PART NUMBER GRADE PART NAME S-1005 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Half Sheets S-1205 1200 S-1505 1600 S-2005 2000 S-1000 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Full Sheets 8-1200 1200 8-1500 1500 S-2000 2000 E-7200 - Mirror Glaze Hi-Tech Finesse Backing Pad E-2000 - Mirror Glaze Hi-Tech Tach Sponge K-400 400 Mirror Glaze Hi-Tech Finesse Sanding Blocks K-1000 1000 K-1500 1500 K-2000 2000 K-3000 3000 Other Applicable Articles: 82-3-3 (G) Color Compatible Spray Primer Chart Ford has released color compatible spray primers for exterior and some interior surfaces. Colored sprayed primers are being used by our "Best-in-Class" competition and are now being implemented at Ford in order to improve process capability and to help in minimizing unsightly paint chipping from stone abrasion. Color keyed (matched) spray primer for exterior body colors is being used in an effort to help in the elimination of unsightly paint chipping from stone abrasion. As with "Best-In-Class" competition, the engine compartment will be left with color compatible primer only and not be topcoated as per past practice. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6085 Figure 5 When any paint repair is required, remember that the vehicle may have a colored primer. Refer to the Spray Primer Chart, Figure 5. This information may be of help in correction of exterior paint color match concerns. (H) Paint Repair For Tinted Clear Coat Ford introduced (Early Spring, 1991) a new paint color using a tinted clearcoat. The first color to use this new system is Rio Red. If a paint repair is necessary, refer to the following procedure for repair instructions. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6086 BACKGROUND The Probe production paint system for Rio Red includes a Medium Green E-Coat primer, a Light Gray spray primer, bright Rio Red (E4) basecoat and a slightly Red tinted clearcoat topcoat. NOTE: BEFORE ANY REPAIRS ARE BEGUN, IT IS CRITICAL THAT PRIMER, RED BASECOAT AND TINTED CLEARCOAT BE SPRAYED ON A TEST PANEL. THE COLOR MATCH IN EACH STEP IS VERY IMPORTANT FOR A SUCCESSFUL REPAIR. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SMALL SPOT REPAIR PROCEDURE 1 Wash the vehicle with detergent soap and water. 2 Wipe the vehicle down with wax and grease remover. 3. Sand the spot using 400 grit paper. Do not sand through the E-coat. 4. Wipe the sanded surface again with wax and grease remover/pre-cleaner. ^ BASF Product # 90 Pre-Kleano ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mix and apply tintable (Light Gray) self-etching or epoxy primer per manufacturer's label instructions. NOTE: COLOR MATCH OF PRIME COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. ^ BASF Product # DE 17 ^ PPG Product # DP 40 ^ S-W Product # E2-G973 ^ DuPont Product # 615S ^ Sikkens Product # 1016 6. Mix and apply bright Rio Red base coat material per manufacturer's label instructions. NOTE: COLOR MATCH OF BASE CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. 7. Mix and apply red tinted clearcoat material per manufacturer's label instructions. NOTE: COLOR MATCH OF TINTED CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. FULL PANEL REPAIR PROCEDURE 1. Wash the vehicle with detergent soap and water. 2. Wipe the vehicle down with wax and grease remover. 3. Sand the complete panel and feather edge into the next panel using 400 grit paper. Do not sand through the E-Coat primer. 4. Wipe the sanded surface with wax and grease remover. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6087 5. Mix and apply tintable (light gray) primer per manufacturer's label instructions. 6. Mix and apply Rio Red basecoat per manufacturer's label instructions. 7. Mix and apply Red tinted clearcoat per manufacturer's label instructions. 8. Mix and apply one coat of non-tinted clearcoat per manufacturer's label instructions. NOTE: COLOR MATCH OF EACH COAT ARE KEY TO COLOR MATCH OF FINISH REPAIR. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C's) OR EXCESS MATERIALS. (I) Paintable Plastics Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6088 Figure 6 The Paintable Plastics Chart, Figure 6, is a summary of widely used plastics in our industry. The standard symbol should be located on the part for ease of material identification. If painting or repair of these plastics is necessary, the following chart identifies those materials which can be painted. Refer to paint manufacturer for specific paint material recommendations. NOTE: MATERIALS MAY REQUIRE PRIME COAT SEE "YES", UNDER "CAN BE PAINTED" COLUMN. (J) 1992 Paint Color Codes Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6089 Figure 7 The 1992 Paint Color Codes are listed in Figure 7. NOTE: REFER TO THE SERVICE LABOR TIME STANDARDS MANUAL AND THE SPECIFIC PROCEDURE WITHIN THIS BULLETIN FOR REIMBURSEMENT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OASIS CODES: 106000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6090 Paint: Technical Service Bulletins Paint - Revised Prices Article No. 85-11-3 REVISED PAINT PRICES FORD 1985 ALL MODELS LINCOLN-MERCURY 1985 ALL MODELS LIGHT TRUCK 1985 ALL MODELS MEDIUM/HEAVY TRUCK 1985 ALL MODELS The following revised paint prices supercede those currently published on page P-4 of the Service Labor Time Standards Manuals. A ............... $ 9.10 G .............$ 14.30 B ................ 9.65 H ............... 16.15 C ............... 10.70 J ............... 17.40 D................ 11.15 K............... 19.50 E ............... 11.95 L ............... 20.50 F ............... 13.90 M............... 35.30 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6091 Technical Service Bulletin # 84171 Date: 840814 Fleet Colors - Revised Paint Code Numbers Article No. 84-17-1 PAINT - CODES - REVISED 1985 FLEET COLOR PAINT CODE NUMBERS FORD 1985 ALL LINCOLN-MERCURY 1985 ALL LIGHT TRUCKS 1985 ALL The following charts list stock numbers for 1985 fleet colors. Other colors used have been released for 1985 service and are referenced in 1985 aftermarket color charts. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Service Refinish Codes FOR THE NEW "330" SPECIAL PAINT SELECTOR COLORS This is a reproduction of the Technical Service Information Bulletin dated 1/28/72. REVISED FLEET COLOR REPAIR PAINT CODE NUMBERS Air dry enamel or lacquer repair paints are available in the following revised list of special order colors. They can be obtained from suppliers of refinishing materials. The Ford Motor Company code number designation and its corresponding vendor code number is given for each color. The color charts corresponding to these codes are in the revised Special Order Paint Selector Book that will be issued to each Ford and Lincoln-Mercury Dealership in mid-February. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6092 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6093 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6094 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6095 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6096 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 6097 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips Seat Cover: Technical Service Bulletins Seat Leather - Cleaning Procedure Tips Article No. 98-17-1 09/01/98 SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 THUNDERBIRD 1984-98 CROWN VICTORIA, ESCORT, MUSTANG 1986-98 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1984-97 COUGAR 1984-98 GRAND MARQUIS, TRACER 1984-99 TOWN CAR 1986-98 SABLE 1993-98 MARK VIII 1995-98 MYSTIQUE 1995-99 CONTINENTAL 1999 COUGAR LIGHT TRUCK: 1983-98 RANGER 1984-96 BRONCO 1984-97 F-250 HD 1984-98 ECONOLINE, F-150, F-250 LD 1986-97 AEROSTAR 1991-98 EXPLORER 1993-98 VILLAGER 1996-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to include the latest level parts and to include a revised Service Procedure. ISSUE The following TSB contains information regarding the cleaning of interior leather seats and trim. Improper cleaning procedures may damage the leather. If seats are not cleaned on a regular basis (every 4-6 weeks), normal wear and tear can cause excessive soiling. ACTION Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to clean soiled seats without damaging the top coat of the leather. The kit contains a leather and vinyl cleaner along with a specially formulated sponge. Refer to the text for cleaning leather seats and trim. The Deluxe Leather Care Kit has been tested and approved for use on all Ford and Lincoln/Mercury leather and vinyl seating surfaces, and if used as directed, should be used for service repairs. Many household cleaners and sponges are too harsh to be used on leather and may actually cause permanent damage to the surface. Use this material on leather and vinyl seats that: ^ show excessive soiling ^ have been stained with coffee, lipstick, etc. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips > Page 6107 Refer to the instructions included in the kit for specific application procedures. After cleaning surface with cleaner and sponge, wipe area with water and a cotton cloth. NOTE AVOID EXCESSIVE APPLICATION OF CLEANER ALONG STITCHING. PART NUMBER PART NAME F8AZ-19G253-AA Deluxe Leather Care Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 101000, 107000, 190000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 6118 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6122 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 6123 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations On Steering Wheel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Cruise Control Switch: Electrical Diagrams Horn & Speed Control Wiring Circuit (Part 1 of 2) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Horn & Speed Control Wiring Circuit (Part 2 of 2) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6135 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6136 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Vacuum Reservoir: > 871819 > Sep > 87 > Speed Control - Loss Of Speed Going Up Grades Cruise Control Vacuum Reservoir: Customer Interest Speed Control - Loss Of Speed Going Up Grades Article No. SPEED CONTROL - LOSS OF SPEED GOING 87-18-19 UP GRADES - 4.9L OR 5.0L ENGINE WITH AOD TRANSMISSION LIGHT TRUCK: 1983-87 E SERIES, F SERIES, BRONCO ISSUE: Loss of speed when going up grades with the speed control engaged and the transmission in overdrive "(D)" may be caused by an insufficient vacuum reserve. Speed loss greater than 10 MPH (16 km/h) will cause the speed control to shut off. ACTION: To correct this, install a speed control vacuum reservoir using the following service procedure. 1. Remove any slack from speed control actuator cable. Make sure the cable allows the throttle lever to return to idle. 2. Install the speed control vacuum reservoir (E3TZ-9E799-B) as follows: a. Locate the 5/16" vacuum hose connecting the engine vacuum to the speed control servo. b. Disconnect the hose at the speed control servo and connect it to the vacuum reservoir port marked "VAC". c. Route 5/16" vacuum hose from the unmarked port on the vacuum reservoir to the open speed control servo port. d. Secure the speed control vacuum reservoir. NOTE: Advise the owner to shift the gear selector to Drive "D" when the vehicle is under a load condition. This information is contained in the Owner Guide. PART NUMBER PART NAME CLASS E3TZ-9E799-B Speed Control Vacuum B Reservoir OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP871819A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 9C735 - Code: 53 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Vacuum Reservoir: > 871819 > Sep > 87 > Speed Control - Loss Of Speed Going Up Grades Cruise Control Vacuum Reservoir: All Technical Service Bulletins Speed Control - Loss Of Speed Going Up Grades Article No. SPEED CONTROL - LOSS OF SPEED GOING 87-18-19 UP GRADES - 4.9L OR 5.0L ENGINE WITH AOD TRANSMISSION LIGHT TRUCK: 1983-87 E SERIES, F SERIES, BRONCO ISSUE: Loss of speed when going up grades with the speed control engaged and the transmission in overdrive "(D)" may be caused by an insufficient vacuum reserve. Speed loss greater than 10 MPH (16 km/h) will cause the speed control to shut off. ACTION: To correct this, install a speed control vacuum reservoir using the following service procedure. 1. Remove any slack from speed control actuator cable. Make sure the cable allows the throttle lever to return to idle. 2. Install the speed control vacuum reservoir (E3TZ-9E799-B) as follows: a. Locate the 5/16" vacuum hose connecting the engine vacuum to the speed control servo. b. Disconnect the hose at the speed control servo and connect it to the vacuum reservoir port marked "VAC". c. Route 5/16" vacuum hose from the unmarked port on the vacuum reservoir to the open speed control servo port. d. Secure the speed control vacuum reservoir. NOTE: Advise the owner to shift the gear selector to Drive "D" when the vehicle is under a load condition. This information is contained in the Owner Guide. PART NUMBER PART NAME CLASS E3TZ-9E799-B Speed Control Vacuum B Reservoir OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP871819A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 9C735 - Code: 53 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 6157 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 Cruise Control Switch: Electrical Diagrams Horn & Speed Control Wiring Circuit (Part 1 of 2) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 Horn & Speed Control Wiring Circuit (Part 2 of 2) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6173 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6174 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description and Operation Vacuum Vent Valve: Description and Operation Fig. 24 Solenoid vacuum valve assembly. Normally closed type Fig. 25 Solenoid vacuum valve assembly. Normally open & normally closed combination type Fig. 26 Solenoid vacuum valve assembly. One port normally open & two port normally closed combination type There are three types of solenoid vacuum valve assemblies, Figs. 24, 25 and 26. The normally closed solenoid vacuum valve assembly incorporates Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description and Operation > Page 6181 two vacuum ports and an atmospheric vent. When the solenoid is de-energized, the vacuum valve assembly outlet port is open to the atmospheric vent and closed to the inlet port. When the solenoid is energized, outlet port is open to the inlet port and closed to the atmospheric vent. Some normally closed solenoid vacuum valves also incorporate a control bleed to prevent contamination from the solenoid vacuum valve from entering the intake manifold. This solenoid valve assembly can be used in the exhaust heat control valve , throttle kicker, air dump or air diverter valve systems. The normally open and normally closed solenoid vacuum valve assembly, incorporates two solenoid valves which operate independently of each other, but are mounted to a single mounting bracket. Each solenoid valve controls a different device. This valve assembly is used to control the Thermactor air bypass and Thermactor diverter. The one port normally open and two port normally closed solenoid vacuum valve assembly also consist of two solenoid valve assemblies mounted to a single mounting bracket. This valve assembly is used to control the A/C throttle kicker and choke pulldown. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description and Operation > Page 6182 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description and Operation > Page 6183 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Locations Audible Warning Device: Locations At RH Side Of Fuse Block Bracket Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 Fig. 42 Seatbelt Warning Indicator Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions Clock: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 Fig. 15 Digital Clock Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Page 6204 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Lamp > Component Information > Description and Operation Coolant Level Indicator Lamp: Description and Operation This lamp will be illuminated when engine coolant level in the radiator drops below a pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to proper level. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Door Switch: Locations Inside Doors Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > EGR Maintenance Light > Component Information > Locations EGR Maintenance Light: Locations On Dash Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: Customer Interest Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > Customer Interest: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 6223 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON Emissions Maintenance Light Reset Switch/Connector: All Technical Service Bulletins Emissions Maintenance Light Stays ON Article No. 85-21-11 LIGHT - EMISSION - STAYS ON LIGHT TRUCK 1985 ALL LIGHT TRUCKS The emission maintenance warning system functions with two microprocessor modules. One module is the inferred mileage sensor (IMS) and the other is the emission maintenance warning (EMW) module. The IMS module is not part of the emission light circuit. The IMS module sends a signal to the engine control assembly (ECA) at a predetermined time which then automatically makes appropriate internal emission control adjustments. The EMW module is a timing device that turns the "EMISSIONS" light on at approximately 60,000 miles, indicating required emission system maintenance. 1985 light trucks built prior to January 1985 have a non-resetable EMW module and require part replacement if the "EMISSIONS" light stays on. Later vehicles are equipped with a resetable EMW module and can be reset as described in the 1985 Car/LightTruck EngineElectrical-Emissions Shop Manual, page 18-6. An additional EMW module is available and is used only for vehicles with approximately 30,000 miles. This module will ensure that the "EMISSIONS" light will still be illuminated as required at 60,000 miles. Locations for the EMW/IMS modules are as follows: Model Location F Series Left side of steering column on instruEconoline ment panel support. Bronco Aerostar Left side of steering column mounted on the EEC-IV processor bracket. Ranger Behind and above the glove box. Bronco II Mounted on the instrument panel. (May require glove box removal.) The IMS and EMW modules are located side by side. The EMW module is the only part that normally requires replacement. It can be identified by a "RESET" sticker and brown plastic housing. The IMS module is black in color and has no stickers. Figure 13 - Module Flange Installation Note E/F Series and Bronco access is limited. Installing a new module may require slotting of the upper mounting hole on the module flange (see Figure 13). This allows starting of the upper screw in the instrument panel support so the module can then be slid under the screw head before tightening. PART NUMBER PART NAME CLASS E5TZ-12B514-A EMW Module - 60K C Resetable E5TZ-12B514-C EMW Module - 30K C Resetable E1TZ-12B514-A IMS Module - No C Adjustments OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 852111 > Oct > 85 > Emissions - Maintenance Light Stays ON > Page 6229 OPERATION: SP12514A85 TIME: 0.3 Hr. - Ranger and Bronco II 0.4 Hr. - Aerostar 0.5 Hr. - F Series, Bronco, Econoline DLR. CODING: Basic Part No. 12B514 - Code: 42 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Ignition Switch: All Technical Service Bulletins Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 6235 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Emissions Maintenance Light Reset Switch/Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emissions Maintenance Light Reset Switch/Connector: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 6241 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge: Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 6248 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 6249 Fuel, Oil & Coolant Gauges & Fuel Tank Selector Wiring Circuit Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention > Page 6254 Fuel Gauge Sender: Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention > Page 6255 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Auxiliary Tank Fuel Gauge Sender Fuel Gauge Sender: Locations Auxiliary Tank Fuel Gauge Sender Attached To Rear Fuel Tank Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Auxiliary Tank Fuel Gauge Sender > Page 6258 Fuel Gauge Sender: Locations Fuel Gauge Sender Attached To Rear Fuel Tank Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > Customer Interest for Instrument Cluster / Carrier: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Instrument Cluster / Carrier: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > Customer Interest for Instrument Cluster / Carrier: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 6267 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Cluster / Carrier: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Instrument Cluster / Carrier: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Cluster / Carrier: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 6273 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Technical Service Bulletins > Page 6274 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation NOTE: This lamp is used only on models with Federal emissions systems. The lamp will be illuminated after approximately 60,000 miles of operation. The amber lens is located on the instrument panel and has the word Emissions, Emiss or EGR printed on it. On 1988 Ranger models with 2.0L/4-122 engine, the lamp lens will indicate Check Engine. After performing the required emission control maintenance, the module must be replaced or reset, depending on type of module used. On module equipped with reset feature, reset the module as follows: 1. Place ignition switch in the Off position. 2. On Aerostar models, the module is located under the instrument panel near the bulkhead connector. On Bronco and F-Series, the module is attached to the instrument cluster to the left of the steering column. On Bronco II and Ranger models, the module is located on the righthand side of the instrument panel below the glove compartment. On E Series models, the module is located under the lefthand side of the instrument panel. 3. On all models, insert a suitable phillips head screwdriver through .2 inch diameter hole located on module near the reset sticker and lightly press down and hold. 4. While still lightly pressing down on screwdriver, turn ignition switch to Run position. The emissions maintenance lamp should remain illuminated for as long as the screwdriver is pressing down. Hold screwdriver in position for approximately five seconds. 5. Remove screwdriver, lamp should go out after approximately two to five seconds, indicating the module has been reset. If lamp fails to go out, repeat reset procedure. Place ignition switch in the Off position. 6. Turn ignition switch to Run position and check to ensure emission maintenance lamp is illuminated for two to five seconds. After approximately two to five seconds the lamp should turn off. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation Fig. 1 Jumper wire connections for resetting Check Engine Lamp. 1985-90 Models w/EEC-IV This lamp will be illuminated when the ignition switch is placed in the On position. After engine is started the lamp should go off, unless a problem has been detected by the EEC-IV system. After diagnosis and repair, the Check Engine/MIL lamp will automatically reset when stored codes are cleared from the EEC-IV system memory. After diagnosis and repair, EEC-IV memory may be cleared of stored codes as follows: 1. With ignition switch in the Off position, connect a jumper wire between Self Test and Self Test Input (STI) connectors, Fig. 1. On Aerostar, the Self Test and STI connectors are gray in color and are located on lefthand fender apron, near the Electronic Engine Control (EEC) relay. On Bronco and F Series, the Self Test and STI connectors are located in the area of the EEC system charcoal canister. On Bronco II and Ranger, the Self Test connector and STI connector are red in color and they are both located on the righthand fender apron near the Electronic Engine Control (EEC) relay. On E Series, the Self Test and the STI connectors are located on the righthand fender apron in the area of the MAP sensor and starter motor relay. 2. Position ignition switch in On position, then disconnect jumper wire from test connector terminals. Disconnect jumper as soon as Check Engine lamp starts flashing. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 6285 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 6294 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 6300 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 6301 Oil Level Warning Indicator: Description and Operation This system is used to indicate a low engine oil level condition. The lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off position. The module may take a few minutes to reset. If the engine is started during this period, the last recorded reading will be displayed. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Inside Doors Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention Fuel Gauge Sender: Technical Service Bulletins Fuel Pump/Sender - Erratic Operation Prevention Article No. 86-16-3 FUEL SYSTEM - FUEL PUMP/SENDER-APPLICATION OF GREASE TO ELECTRICAL TERMINALS FORD 1985-86 ESCORT, EXP, TEMPO, MUSTANG, LTD, THUNDERBIRD LINCOLN-MERCURY 1985-86 LYNX, TOPAZ, CAPRI, MARQUIS, COUGAR, MARK VII, CONTINENTAL LIGHT TRUCK 1985-86 RANGER, BRONCO II, AEROSTAR, BRONCO, E SERIES, F SERIES To prevent erratic operation of the fuel gauge or the in-tank fuel pump, a generous application of electrical grease should be applied to the terminals of the fuel pump/sender when service is required. The electrical grease will prevent corrosion and reduce the chance of a repeat repair. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention > Page 6319 Fuel Gauge Sender: Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Pump/Sender - Erratic Operation Prevention > Page 6320 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Auxiliary Tank Fuel Gauge Sender Fuel Gauge Sender: Locations Auxiliary Tank Fuel Gauge Sender Attached To Rear Fuel Tank Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Auxiliary Tank Fuel Gauge Sender > Page 6323 Fuel Gauge Sender: Locations Fuel Gauge Sender Attached To Rear Fuel Tank Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 6334 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test > Page 6339 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Manual Transmission Backup Lamp Switch: Locations Manual Transmission Attached To Shifter Assembly Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Manual Transmission > Page 6352 Backup Lamp Switch: Locations 3-Speed Manual Transmission Near Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Fig. 21 Exterior Lamp (Hazard, Stop & Turn) Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6362 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 Dome Lamp: Electrical Diagrams Cargo, Courtesy, Dome & Lamps-On Warning System Wiring Circuit (Part 1 of 2) Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 Fig. 11 Cargo, Courtesy, Dome & Lamps-On Warning System Wiring Circuit (Part 2 of 2). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Inside Doors Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 Fig. 21 Exterior Lamp (Hazard, Stop & Turn) Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Headlamp Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6385 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6386 Fig. 30 Headlamp Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6392 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6393 Fig. 30 Headlamp Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision Headlamp Switch: Technical Service Bulletins Headlamp Light Switch - Schematic Revision Article No. 91-11B-35 06/14/91 ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1981 - PAGES 40 AND 41 EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1982 - PAGE 40 - EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1984 - PAGE 34 - EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1985 - PAGE 34 - EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED LIGHT TRUCK: 1981 F-150-350 SERIES 1981-82 BRONCO 1984-85 ECONOLINE ISSUE: The connections of Exterior Lights (Marker, Park, License) to the Light Switch are inaccurately shown in the schematics of the following Electrical/Vacuum Troubleshooting Manuals: Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6398 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6399 ^ 1981 Bronco/F-Series Pages 40 and 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6400 ^ 1982 Bronco/F-Series Page 40 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6401 ^ 1984 Econoline Page 34 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6402 ^ 1985 Econoline Page 34 ACTION: Refer to the pages in this TSB article for the revised schematics. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6403 OASIS CODES: 290000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Technical Service Bulletins > Page 6404 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6409 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6410 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6411 Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6412 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 Fig. 22 Exterior Lamps (License, Marker & Park) Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 Fig. 22 Exterior Lamps (License, Marker & Park) Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Headlamp Control Module: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 Fig. 30 Headlamp Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6435 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6436 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6437 Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6438 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Manual Transmission Backup Lamp Switch: Locations Manual Transmission Attached To Shifter Assembly Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Manual Transmission > Page 6447 Backup Lamp Switch: Locations 3-Speed Manual Transmission Near Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6451 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Inside Doors Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 Fig. 21 Exterior Lamp (Hazard, Stop & Turn) Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 Fig. 30 Headlamp Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision Headlamp Switch: Technical Service Bulletins Headlamp Light Switch - Schematic Revision Article No. 91-11B-35 06/14/91 ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1981 - PAGES 40 AND 41 EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1982 - PAGE 40 - EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1984 - PAGE 34 - EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1985 - PAGE 34 - EXTERIOR LIGHTS CONNECTIONS TO LIGHT SWITCH REVISED LIGHT TRUCK: 1981 F-150-350 SERIES 1981-82 BRONCO 1984-85 ECONOLINE ISSUE: The connections of Exterior Lights (Marker, Park, License) to the Light Switch are inaccurately shown in the schematics of the following Electrical/Vacuum Troubleshooting Manuals: Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6472 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6473 ^ 1981 Bronco/F-Series Pages 40 and 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6474 ^ 1982 Bronco/F-Series Page 40 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6475 ^ 1984 Econoline Page 34 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6476 ^ 1985 Econoline Page 34 ACTION: Refer to the pages in this TSB article for the revised schematics. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Headlamp Light Switch - Schematic Revision > Page 6477 OASIS CODES: 290000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Page 6478 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 Fig. 21 Exterior Lamp (Hazard, Stop & Turn) Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 6486 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Turn Flasher > Page 6495 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Lamp: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6500 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6501 Fig. 21 Exterior Lamp (Hazard, Stop & Turn) Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6507 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6508 Fig. 21 Exterior Lamp (Hazard, Stop & Turn) Wiring Circuit. 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 6509 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations On Driver's Door Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Locations Power Window Circuit Breaker: Locations Circuit Location Amps Power Door Locks .................Fuse Panel.....................30 Power Windows.....................In Line At Junction Block......20 Windshield Wiper..................Fuse Panel....................7.5 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations On Driver's Door Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip Window Glass: Customer Interest Vent Windows - May Stick to Weatherstrip GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES BUILT BEFORE 4/04/88 Article No. 88-14-1 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip making them hard to open. In some cases, the high opening efforts may cause the weatherstrip to pull out of the vent division bar. ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following service procedure. FIGURE 1 1. Open the vent window all the way. 2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 6540 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 87112 > Jun > 87 > Manual Vent Windows - Hard to Open Window Glass: Customer Interest Manual Vent Windows - Hard to Open Article No. GLASS - VENT WINDOWS - MANUAL 87-11-2 HARD TO OPEN FORD: 1984-87 ALL CAR LINES LINCOLN-MERCURY: 1984-87 ALL CAR LINES LIGHT TRUCK: 1984-87 ALL LIGHT TRUCK LINES Figure 2 - Article 87-11-2 ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip which makes them hard to open. ACTION: To correct this, apply a thin coating of Silicone Lubricant (COAZ-19553-AA) to the vent window weatherstrip as shown in Figure 2. This lubricant can be applied during dealer prep and/or normal customer service visits. NOTE: DO NOT USE AEROSOL SPRAY CANS. PART NUMBER PART NAME CLASS COAZ-19553-AA Silicone Lubricant B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871102A - Both sides TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7021448 Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Window Glass: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 6554 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 93211 > Oct > 93 > Glass - Iridescence or Mottling In Tempered Glass Window Glass: All Technical Service Bulletins Glass - Iridescence or Mottling In Tempered Glass Article No. 93-21-1 10/13/93 GLASS - "IRIDESCENCE" OR "MOTTLING" IN TEMPERED GLASS FORD: 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-88 EXP 1986-94 TAURUS 1989-93 FESTIVA LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1988-94 CONTINENTAL 1991-94 CAPRI, TRACER 1993-94 MARK VIII LIGHT TRUCK: 1984-90 BRONCO II 1984-94 ECONOLINE, F-150-350 SERIES, RANGER 1986-94 AEROSTAR 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: Vehicles may exhibit iridescent spots or "mottling" in tempered glass under some lighting conditions. This condition is caused by the tempering process. ACTION: Explain to customers that "iridescence" or "mottling" of tempered glass is a normal condition and that glass replacement is neither warranted nor necessarily effective in resolving the condition. DESCRIPTION OF CONDITION The somewhat iridescent grayish or blueish and fairly geometric spots detected in side and rear window tempered glass are characteristic of tempered glass. The mottled appearance is noted only under certain conditions of lighting. The occurrence of mottling does not affect glass quality or durability and cannot be reduced by scouring the glass surface. The boldness of the mottled pattern in a given glass may vary, depending upon lighting conditions, but may appear intensified if viewed through polarized sunglasses. CAUSES OF CONDITION Atmospheric dust and other angular reflections can cause changes in the polarized properties of natural light. This polarization, combined with the light polarizing properties imparted to tempered glass by the forces of tension and compression (during the tempering process), cause the iridescent or mottled appearance. These are the same forces of compression and tension which make tempered glass so remarkably strong. Windshields, which are annealed rather than tempered, do not exhibit iridescence. OTHER APPLICABLE ARTICLES: 83-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip Window Glass: All Technical Service Bulletins Vent Windows - May Stick to Weatherstrip GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES BUILT BEFORE 4/04/88 Article No. 88-14-1 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip making them hard to open. In some cases, the high opening efforts may cause the weatherstrip to pull out of the vent division bar. ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following service procedure. FIGURE 1 1. Open the vent window all the way. 2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 6563 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 8852 > Mar > 88 > Manual Vent Windows - Difficult to Open Window Glass: All Technical Service Bulletins Manual Vent Windows - Difficult to Open GLASS - MANUAL VENT WINDOWS HARD TO OPEN Article No. 88-5-2 FORD: 1980-88 CROWN VICTORIA 1981-86 THUNDERBIRD 1981-87 ESCORT 1984-86 LTD LINCOLN-MERCURY: 1980-88 GRAND MARQUIS 1981-86 LYNX, COUGAR 1984-86 MARQUIS LIGHT TRUCK: 1980-88 E-SERIES, F-SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR ISSUE: Hard to open pivoting type vent windows may be caused by the glass sticking to the weatherstrip on the division bar. The weatherstrip is often pulled out of the division bar when this condition is present. FIGURE 1 ACTION: To correct this, apply a strip of clear pressure sensitive tape on the inside vertical edge of the vent window glass, Figure 1. PART NUMBER PART NAME CLASS E8AZ-19627-A Clear Pressure Sensitive B Tape OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 880502A - Both vent windows TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7021402 Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 87112 > Jun > 87 > Manual Vent Windows - Hard to Open Window Glass: All Technical Service Bulletins Manual Vent Windows - Hard to Open Article No. GLASS - VENT WINDOWS - MANUAL 87-11-2 HARD TO OPEN FORD: 1984-87 ALL CAR LINES LINCOLN-MERCURY: 1984-87 ALL CAR LINES LIGHT TRUCK: 1984-87 ALL LIGHT TRUCK LINES Figure 2 - Article 87-11-2 ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip which makes them hard to open. ACTION: To correct this, apply a thin coating of Silicone Lubricant (COAZ-19553-AA) to the vent window weatherstrip as shown in Figure 2. This lubricant can be applied during dealer prep and/or normal customer service visits. NOTE: DO NOT USE AEROSOL SPRAY CANS. PART NUMBER PART NAME CLASS COAZ-19553-AA Silicone Lubricant B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION: SP871102A - Both sides TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7021448 Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Window Glass: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 6577 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Glass: > 93211 > Oct > 93 > Glass - Iridescence or Mottling In Tempered Glass Window Glass: All Technical Service Bulletins Glass - Iridescence or Mottling In Tempered Glass Article No. 93-21-1 10/13/93 GLASS - "IRIDESCENCE" OR "MOTTLING" IN TEMPERED GLASS FORD: 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-88 EXP 1986-94 TAURUS 1989-93 FESTIVA LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1988-94 CONTINENTAL 1991-94 CAPRI, TRACER 1993-94 MARK VIII LIGHT TRUCK: 1984-90 BRONCO II 1984-94 ECONOLINE, F-150-350 SERIES, RANGER 1986-94 AEROSTAR 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: Vehicles may exhibit iridescent spots or "mottling" in tempered glass under some lighting conditions. This condition is caused by the tempering process. ACTION: Explain to customers that "iridescence" or "mottling" of tempered glass is a normal condition and that glass replacement is neither warranted nor necessarily effective in resolving the condition. DESCRIPTION OF CONDITION The somewhat iridescent grayish or blueish and fairly geometric spots detected in side and rear window tempered glass are characteristic of tempered glass. The mottled appearance is noted only under certain conditions of lighting. The occurrence of mottling does not affect glass quality or durability and cannot be reduced by scouring the glass surface. The boldness of the mottled pattern in a given glass may vary, depending upon lighting conditions, but may appear intensified if viewed through polarized sunglasses. CAUSES OF CONDITION Atmospheric dust and other angular reflections can cause changes in the polarized properties of natural light. This polarization, combined with the light polarizing properties imparted to tempered glass by the forces of tension and compression (during the tempering process), cause the iridescent or mottled appearance. These are the same forces of compression and tension which make tempered glass so remarkably strong. Windshields, which are annealed rather than tempered, do not exhibit iridescence. OTHER APPLICABLE ARTICLES: 83-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Handle > Component Information > Technical Service Bulletins > Window Regulator Handle - Improved Attachment Window Handle: Technical Service Bulletins Window Regulator Handle - Improved Attachment Article No. 85-3-1 HANDLE - DOOR, WINDOW REGULATOR - IMPROVED ATTACHMENT FORD 1984-85 ALL LINCOLN-MERCURY 1984-85 ALL LIGHT TRUCKS 1984-85 ALL MEDIUM/HEAVY TRUCKS 1984-85 ALL Loose window regulator handles or inoperative manual windows may be caused by loose window regulator handle attaching screws. Replace the attaching screw with a new "torx drive" attaching screw which provides a better attachment, and torque to 33-48 in. lbs. 1. Remove window regulator handle attaching screw. 2. Install "torx drive" window regulator handle attaching screw and torque to 33-48 in. lbs. PART NUMBER PART NAME CLASS 390334-S7 Screw ("torx drive") S OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP23342A84 TIME: 1 or 2 - 0.2 Hr. OPERATION: SP23342B84 TIME: 3 or 4 - 0.3 Hr. DLR. CODING: Basic Part No. 7023342 Code: 57 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > Customer Interest: > 892013 > Oct > 89 > Front Door Window - Jams In Full Up Position Window Regulator: Customer Interest Front Door Window - Jams In Full Up Position Article No. 89-20-13 GLASS - POWER - FRONT DOOR - JAMS IN THE "UP" POSITION - VEHICLES BUILT BEFORE 5/15/89 LIGHT TRUCK: 1985-89 ECONOLINE ISSUE: The front door power window may jam in the full "up" position. This may happen if the drive motor runs past the gear teeth on the window regulator quadrant. Without proper gear engagement, the window cannot be lowered. ACTION: Install a new design regulator that has additional teeth on the quadrant. Refer to the appropriate model year Light Truck Shop Manual, Section 42-08 for removal and installation procedures. PART NUMBER PART NAME CLASS E9UZ-1623208-B Regulator R.H. - Less Motor B Drive E9UZ-1523209-8 Regulator L.H. - Less Motor B Drive WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892013A Install Both Regulators 1.0 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7023208 41 OASIS CODES: 1300, 2900 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Regulator: > 892013 > Oct > 89 > Front Door Window - Jams In Full Up Position Window Regulator: All Technical Service Bulletins Front Door Window - Jams In Full Up Position Article No. 89-20-13 GLASS - POWER - FRONT DOOR - JAMS IN THE "UP" POSITION - VEHICLES BUILT BEFORE 5/15/89 LIGHT TRUCK: 1985-89 ECONOLINE ISSUE: The front door power window may jam in the full "up" position. This may happen if the drive motor runs past the gear teeth on the window regulator quadrant. Without proper gear engagement, the window cannot be lowered. ACTION: Install a new design regulator that has additional teeth on the quadrant. Refer to the appropriate model year Light Truck Shop Manual, Section 42-08 for removal and installation procedures. PART NUMBER PART NAME CLASS E9UZ-1623208-B Regulator R.H. - Less Motor B Drive E9UZ-1523209-8 Regulator L.H. - Less Motor B Drive WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892013A Install Both Regulators 1.0 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7023208 41 OASIS CODES: 1300, 2900 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Regulator: > 8531 > Feb > 85 > Window Regulator Handle Improved Attachment Window Regulator: All Technical Service Bulletins Window Regulator Handle - Improved Attachment Article No. 85-3-1 HANDLE - DOOR, WINDOW REGULATOR - IMPROVED ATTACHMENT FORD 1984-85 ALL LINCOLN-MERCURY 1984-85 ALL LIGHT TRUCKS 1984-85 ALL MEDIUM/HEAVY TRUCKS 1984-85 ALL Loose window regulator handles or inoperative manual windows may be caused by loose window regulator handle attaching screws. Replace the attaching screw with a new "torx drive" attaching screw which provides a better attachment, and torque to 33-48 in. lbs. 1. Remove window regulator handle attaching screw. 2. Install "torx drive" window regulator handle attaching screw and torque to 33-48 in. lbs. PART NUMBER PART NAME CLASS 390334-S7 Screw ("torx drive") S OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP23342A84 TIME: 1 or 2 - 0.2 Hr. OPERATION: SP23342B84 TIME: 3 or 4 - 0.3 Hr. DLR. CODING: Basic Part No. 7023342 Code: 57 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Regulator: > 8531 > Feb > 85 > Window Regulator Handle Improved Attachment Window Regulator: All Technical Service Bulletins Window Regulator Handle - Improved Attachment Article No. 85-3-1 HANDLE - DOOR, WINDOW REGULATOR - IMPROVED ATTACHMENT FORD 1984-85 ALL LINCOLN-MERCURY 1984-85 ALL LIGHT TRUCKS 1984-85 ALL MEDIUM/HEAVY TRUCKS 1984-85 ALL Loose window regulator handles or inoperative manual windows may be caused by loose window regulator handle attaching screws. Replace the attaching screw with a new "torx drive" attaching screw which provides a better attachment, and torque to 33-48 in. lbs. 1. Remove window regulator handle attaching screw. 2. Install "torx drive" window regulator handle attaching screw and torque to 33-48 in. lbs. PART NUMBER PART NAME CLASS 390334-S7 Screw ("torx drive") S OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP23342A84 TIME: 1 or 2 - 0.2 Hr. OPERATION: SP23342B84 TIME: 3 or 4 - 0.3 Hr. DLR. CODING: Basic Part No. 7023342 Code: 57 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip Window Seal: Customer Interest Vent Windows - May Stick to Weatherstrip GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES BUILT BEFORE 4/04/88 Article No. 88-14-1 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip making them hard to open. In some cases, the high opening efforts may cause the weatherstrip to pull out of the vent division bar. ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following service procedure. FIGURE 1 1. Open the vent window all the way. 2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 6616 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip Window Seal: All Technical Service Bulletins Vent Windows - May Stick to Weatherstrip GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES BUILT BEFORE 4/04/88 Article No. 88-14-1 FORD: 1984-88 ALL CAR LINES LINCOLN-MERCURY: 1984-88 ALL CAR LINES MERKUR: 1985-88 ALL CAR LINES LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES ISSUE: Manual vent windows that are not opened very often may stick to the vent window weatherstrip making them hard to open. In some cases, the high opening efforts may cause the weatherstrip to pull out of the vent division bar. ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following service procedure. FIGURE 1 1. Open the vent window all the way. 2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 1. Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 6622 FIGURE 2 3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure 2. 4. Close and open vent window to make sure window operates correctly. NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300 EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN. OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 881401A TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Windshield/Interior Glass - Fog/Film Windshield: Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Windshield/Interior Glass - Fog/Film > Page 6627 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 Windshield Washer Relay: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6644 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6645 Wiper Relay: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6646 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6652 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6653 Windshield Washer Switch: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6654 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6660 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6661 Wiper Switch: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 6663 Wiper Switch: Testing and Inspection Fig. 4 Wiper Switch Continuity Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 6664 Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 6665 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 6666 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Motor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 Windshield Washer Motor: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Pump: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Windshield Washer Pump: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 Windshield Washer Relay: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 Windshield Washer Switch: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Wiper Motor: Locations LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6706 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6707 Wiper Motor: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 6709 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 6710 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions Interval Governor: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Interval Governor: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 Wiper Relay: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) 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 (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Symbol Identification Wire Color Code Identification Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 Wiper Switch: Electrical Diagrams Fig. 44 Windshield Wiper/Washer Wiring Circuit (Less Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 Fig. 45 Windshield Wiper/Washer Wiring Circuit (With Interval). 1985 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 6733 Wiper Switch: Testing and Inspection Fig. 4 Wiper Switch Continuity Test Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 6734 Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350 Ford E 150 Van Workshop Manual (V8-302 5.0L (1985)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 6735 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.