Factory Workshop Manual
Make
Ford
Model
E 250 Van
Engine and year
V8-460 7.5L (1982)
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This manual was submitted by
Anonymous
Date
1st January 2018
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by System > A L L Diagnostic Trouble Codes Engine Controls > System Information > System Diagnosis > Transmisson Codes
A L L Diagnostic Trouble Codes - Engine Controls: Testing and Inspection Transmisson Codes
For Transmission related codes, proceed to Computers and Control Systems.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by System > A L L Diagnostic Trouble Codes Trans and Drivetrain > System Information > System Diagnosis
A L L Diagnostic Trouble Codes - Trans and Drivetrain: Testing and Inspection
For Transmission related codes, proceed to Computers and Control Systems.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations
Lower LH Cowl Near Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module >
Component Information > Locations
Cruise Control Module: Locations
LH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module >
Component Information > Locations > Page 20
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module
> Component Information > Locations
Fuel Distance/Mileage Module: Locations
Near ECA Under RH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Horn Relay: Locations
Horn Relay Location
Under LH Side Of I/P.
Under LH Side Of I/P, With Speed Control
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 29
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 30
Horn Relay: Testing and Inspection
Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 31
Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 32
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Trailer Lighting Relay: Locations
LH Rear Fender Below LH Taillight
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Protection
Relay > Component Information > Locations
Power Protection Relay: Locations
In Engine Compartment On LH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 >
Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Engine Control Module: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 >
Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 50
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 >
Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 51
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 >
Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 52
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 >
Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 53
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 >
Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 54
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 >
Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 55
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 >
Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 56
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition
Engine Control Module: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 62
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 63
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 64
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 65
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 66
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 67
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 68
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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
69
Engine Control Module: Locations
LH Rear Of Engine Compartment
LH Fender Apron Near Ignition Module
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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
70
Engine Control Module: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
RH Fender Apron w/EEC
Attached To Top Of RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 74
Main Relay (Computer/Fuel System): Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
RH Fender Apron w/EEC
Attached To Top Of RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 79
Main Relay (Computer/Fuel System): Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Description and Operation
Ignition Control Module: Description and Operation
Typical Ignition System
The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic
pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short
period of time. High voltage is created each time the magnetic field is built up and collapsed. The
red ignition module wire provides operating voltage for the module's electronic components in the
Run mode. The white module wire and start bypass provide increased voltage for the module and
coil during Start mode.
Ignition Modules
Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control
signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the
Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this
second signal, the UIM provides additional spark timing control for certain operating conditions by
shutting off the ignition coil current flow at a different time than with just the distributor pick-up
signal.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Description and Operation > Page 84
Module Identification Chart
For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura
Spark II has 6 wire connector while Dura Spark III has a 5 wire connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
RH Fender Apron w/EEC
On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations
Power Window Relay: Locations
Lower LH Cowl Near Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations
Wiper Control Module: Locations
Upper LH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Radio
Power Boost Switch > Component Information > Locations
Radio Power Boost Switch: Locations
Attached To RH Cowl
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Locations
Brake Fluid Pressure Sensor/Switch: Locations
Frame Wiring.
On LH Frame At No. 2 Crossmember
Applicable to: 138 Standard Van
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information >
Specifications
Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Testing and Inspection
Brake Switch (Cruise Control): Testing and Inspection
Perform this test only when brake application will not disconnect the speed control system.
1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If
more than 6 lbs. is required, check brake pedal actuation and stop lamp switch.
2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch.
3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire
w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire
w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983
F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87
Aerostar.
4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on
1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on
1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco
II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5
volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Service and Repair
Clutch Switch: Service and Repair
1. Remove bracket mounting screw(s).
2. Disconnect electrical connector and remove switch and bracket assembly.
3. Remove switch from bracket.
4. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations
Cruise Control Switch: Locations
On Steering Wheel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations > Page 124
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations > Page 125
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Testing and Inspection
Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Auxiliary Blower Switch
Blower Motor Switch: Locations Auxiliary Blower Switch
RH Side Of Function Control
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Auxiliary Blower Switch > Page 134
Blower Motor Switch: Locations Front Blower Switch
LH Side Of Control Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Locations
Evaporator Temperature Sensor / Switch: Locations
A/C EVAPORATOR DE-ICING SWITCH
RH Dash Panel Attached To Evaporator
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations
Door Switch: Locations
Inside Driver's Door
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Automatic Transmission
Backup Lamp Switch: Locations Automatic Transmission
Attached To Base Of Steering Column
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Automatic Transmission > Page 150
Backup Lamp Switch: Locations Manual Transmission
Attached To Shifter Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Automatic Transmission > Page 151
Backup Lamp Switch: Locations 3-Speed Manual Transmission
Near Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
Top Of Brake Pedal Support
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 155
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations
Door Switch: Locations
Inside Driver's Door
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations
Headlamp Dimmer Switch: Locations
LH Floor Board
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Service and Repair
Headlamp Switch: Service and Repair
Fig. 5 Light Switch
E-100---350
1. Disconnect battery ground cable.
2. Remove knob and shaft assembly by depressing release button on switch housing and pulling
straight out.
3. Remove bezel or mounting nut from switch, Fig. 4.
4. Disconnect electrical connector from switch and remove switch from vehicle.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Upper LH Side Of Steering Column
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 168
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations
Barometric Pressure Sensor: Locations
In Engine Compartment On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Testing and
Inspection > Barometric Pressure Sensor
Barometric Pressure Sensor: Testing and Inspection Barometric Pressure Sensor
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values
in chart.
3. Replace switch if resistance is not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Testing and
Inspection > Barometric Pressure Sensor > Page 176
Barometric Pressure Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
RH Front Of Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
180
Crankshaft Position Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations
EGR Valve Position Sensor: Locations
LH Side Of V8-302/5.
At Center Engine To Rear Of Carburetor
Applicable to: 0L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and
Inspection > Component Testing
Intake Air Temperature Sensor: Testing and Inspection Component Testing
NOTE: Prior to performing any test on this system, insure that temperature switch is above 65° F.
1. Disconnect connector from wiring harness.
2. Connect an ohmmeter or self-powered test light to temperature switch connector terminals.
3. Cool the switch to below 40° F by spraying with Refrigerant 12.
CAUTION: Do not spray refrigerant with engine running, as any refrigerant drawn into the
carburetor and burned in the engine will produce poisonous phosgene gas. Conduct this procedure
in well ventilated area.
4. When switch is cooled below 40° F. a.
On type 1 switches, the internal switch contacts should open. The ohmmeter should read maximum
resistance or the test light should be off. If switch does not open below 40° F, replace switch.
b. On type 2 switches, the internal switch contacts should close. The ohmmeter should read zero
resistance and the test light should be on. If test light does not go on or ohmmeter indicates a
resistance of 1 ohm or more, replace switch.
5. Increase switch temperature to above 70° F by placing palm of hand on metal surface of switch
or by starting engine and allowing the exhaust manifold heat to increase the intake air temperature.
6. When switch temperature is above 70° F. a.
On type 1 switches, the internal switch contacts should close. The ohmmeter should read zero
resistance and the test light should be on. If test light does not go on or ohmmeter indicates a
resistance of 1 ohm or more, replace switch.
b. On type 2 switches, the internal switch contacts should open. The ohmmeter should read
maximum resistance or the test light should be off. If switch does not open, replace switch.
c. If switch is replaced, check operation of new switch before connecting harness connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and
Inspection > Component Testing > Page 188
Intake Air Temperature Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page
192
Knock Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
RH Fender Apron w/EEC
In Engine Compartment On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 196
Manifold Pressure/Vacuum Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
At LH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection >
Speed Sensor Test
Vehicle Speed Sensor: Testing and Inspection Speed Sensor Test
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection >
Speed Sensor Test > Page 202
Vehicle Speed Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection >
Page 203
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations
EGR Valve Position Sensor: Locations
LH Side Of V8-302/5.
At Center Engine To Rear Of Carburetor
Applicable to: 0L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations
Fuel Tank Selector Switch: Locations
LH Side Of I/P Near Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep >
84 > Fuel System - Stalls/No Start/Hesitation/ Stumble
Fuel Pump Inertia Switch: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/
Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep >
84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 220
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel
System - Stalls/No Start/Hesitation/ Stumble
Fuel Pump Inertia Switch: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel
System - Stalls/No Start/Hesitation/ Stumble > Page 226
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
RH Front Of Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 231
Crankshaft Position Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Service and Repair
Ignition Switch: Service and Repair
Fig. 3 Ignition switch replacement
1. Disconnect battery ground cable.
2. Remove steering column shroud and lower the steering column.
3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts.
4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Description and Operation
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 238
Knock Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations
Seat Belt Buckle Switch: Locations
Part Of Driver's Seat Belt
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Pedal Position
Switch <--> [Clutch Switch] > Component Information > Testing and Inspection
Clutch Pedal Position Switch: Testing and Inspection
Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized
tools near this switch.
1. If the switch is open when the clutch pedal is released, speed control will not operate. This must
be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher
when performing the clutch switch test.
2. Disconnect switch pigtail connector from speed control harness connector and connect an
ohmmeter to the two switch connector terminals.
3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With
clutch pedal fully depressed, the circuit should be open.
4. If switch does not function as described, remove and replace switch.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Service and Repair
Ignition Switch: Service and Repair
Fig. 3 Ignition switch replacement
1. Disconnect battery ground cable.
2. Remove steering column shroud and lower the steering column.
3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts.
4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Location For C6 Transmission
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 253
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Technical Service Bulletins > Customer Interest for Washer Fluid Level Switch: >
84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On
Washer Fluid Level Switch: Customer Interest Wiper/Washer - Low Fluid Warning Light Stays On
Article No. 84-21-9
WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON
FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT
LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING
LIGHT
LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT
On some vehicles equipped with low fluid warning light, the light may stay on even when the
washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that
has not been mixed with water according to the instructions. The undiluted washer solution is
absorbed by the float resulting in the float sinking.
When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions
on the can must be followed. Mixing the concentrated washer fluid with water will stop the float
from sinking.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Washer Fluid
Level Switch: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On
Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light
Stays On
Article No. 84-21-9
WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON
FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT
LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING
LIGHT
LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT
On some vehicles equipped with low fluid warning light, the light may stay on even when the
washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that
has not been mixed with water according to the instructions. The undiluted washer solution is
absorbed by the float resulting in the float sinking.
When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions
on the can must be followed. Mixing the concentrated washer fluid with water will stop the float
from sinking.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations
Wiper Switch: Locations
Upper LH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 271
Wiper Switch: Testing and Inspection
Fig. 4 Wiper Switch Continuity Test
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 272
Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 273
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 274
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer
Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull
Alignment: Customer Interest Steering - Drift/Pull
Article No. 85-19-15
STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT
LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350
A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift
or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to
increase the front wheel caster angle on either or both wheels to balance the caster split to correct
a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the
front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can
increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to
decrease caster.
To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the
following procedure is suggested:
1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop
Manual and choose the appropriate paper template applicable to the vehicle model.
Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM
2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a
typical arm modification for the right hand radius arm. One template per vehicle model is used to
modify both the right and left hand radius arms. When modifying the right hand arm, position the
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer
Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 284
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer
Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 285
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer
Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 286
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer
Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 287
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer
Interest for Alignment: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear
Alignment: Customer Interest Tires - Front Outside Edge Wear
Article No. 85-19-16
TIRE WEAR - FRONT - OUTSIDE EDGE
LIGHT TRUCK 1976-86 E100-150
Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by
excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15
can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit
contains complete instructions for modifying the front radius arms and mounting a metal adjusting
cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch
along two sides of the cam to the lower flange of the radius arm.
Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5
degrees. Increasing caster more than 3 degrees is not recommended since this may cause
complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased
on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built
into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of
each axle.
Three other significant factors may also contribute to outboard shoulder wear. They are excessive
toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After
any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to
extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life.
PART NUMBER PART NAME CLASS
E5TZ-3K064-A Kit Caster Adjustment C
OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME:
4.6 Hrs.
OPERATION: 3001A TIME:
0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull
Alignment: All Technical Service Bulletins Steering - Drift/Pull
Article No. 85-19-15
STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT
LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350
A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift
or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to
increase the front wheel caster angle on either or both wheels to balance the caster split to correct
a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the
front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can
increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to
decrease caster.
To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the
following procedure is suggested:
1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop
Manual and choose the appropriate paper template applicable to the vehicle model.
Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM
2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a
typical arm modification for the right hand radius arm. One template per vehicle model is used to
modify both the right and left hand radius arms. When modifying the right hand arm, position the
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 297
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 298
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 299
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 300
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear
Alignment: All Technical Service Bulletins Tires - Front Outside Edge Wear
Article No. 85-19-16
TIRE WEAR - FRONT - OUTSIDE EDGE
LIGHT TRUCK 1976-86 E100-150
Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by
excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15
can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit
contains complete instructions for modifying the front radius arms and mounting a metal adjusting
cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch
along two sides of the cam to the lower flange of the radius arm.
Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5
degrees. Increasing caster more than 3 degrees is not recommended since this may cause
complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased
on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built
into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of
each axle.
Three other significant factors may also contribute to outboard shoulder wear. They are excessive
toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After
any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to
extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life.
PART NUMBER PART NAME CLASS
E5TZ-3K064-A Kit Caster Adjustment C
OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME:
4.6 Hrs.
OPERATION: 3001A TIME:
0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 305
Alignment: By Symptom
Technical Service Bulletin # 851916 Date: 850901
Tires - Front Outside Edge Wear
Article No. 85-19-16
TIRE WEAR - FRONT - OUTSIDE EDGE
LIGHT TRUCK 1976-86 E100-150
Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by
excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15
can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit
contains complete instructions for modifying the front radius arms and mounting a metal adjusting
cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch
along two sides of the cam to the lower flange of the radius arm.
Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5
degrees. Increasing caster more than 3 degrees is not recommended since this may cause
complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased
on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built
into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of
each axle.
Three other significant factors may also contribute to outboard shoulder wear. They are excessive
toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After
any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to
extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life.
PART NUMBER PART NAME CLASS
E5TZ-3K064-A Kit Caster Adjustment C
OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME:
4.6 Hrs.
OPERATION: 3001A TIME:
0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36
Technical Service Bulletin # 851915 Date: 850926
Steering - Drift/Pull
Article No. 85-19-15
STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT
LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350
A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift
or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to
increase the front wheel caster angle on either or both wheels to balance the caster split to correct
a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the
front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can
increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to
decrease caster.
To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the
following procedure is suggested:
1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop
Manual and choose the appropriate paper template applicable to the vehicle model.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 306
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 307
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 308
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 309
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 310
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 311
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 312
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 313
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 314
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical
Service Bulletins for Alignment: > Page 315
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 316
Alignment: Specifications
Camber Caster Toe
Ride Height 3.25-3.50 in -1 3/4 to -1/4 deg +9 to +10 1/2 deg 1/32 in
3.50-3.75 in -1 1/2 to + 1/4 deg +8 1/2 to +9 3/4 deg 1/32 in
4.00-4.25 in -1/2 to + 1 1/4 deg +7 1/8 to +8 1/2 deg 1/32 in
4.25-4.50 in 0 to + 1 3/4 deg +6 1/2 to +7 3/4 deg 1/32 in
4.50-4.75 in + 1/2 to +2 1/4 deg +5 3/4 to +7 deg 1/32 in
5.00-5.25 in +1 1/2 to + 3 1/4 deg +4 5/8 to +6 deg 1/32 in
5.25-5.50 in +2 to +3 3/4 deg +4 to +5 1/2 deg 1/32 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 317
Alignment: Service and Repair
Fig. 1 Measuring Ride Height
Fig. 7 Measuring riding height. 1980---85 F-100---350 & Bronco
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 318
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications
Fuel Pressure: Specifications
Fuel Pump Pressure (Mechanical) ......................................................................................................
........................................................... 6-8 psi (at idle) Fuel Pump Pressure (Electrical) .....................
.............................................................................................................................................................
4.3 psi
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications > Page 323
Fuel Pressure: Testing and Inspection
1. Connect a suitable pressure gauge (0-15 psi) to the carburetor end of the fuel line (no "T" is
required). 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. The fuel
pump pressure should read 6-8 psi at normal curb idle speed, with the transmission in NEUTRAL,
the engine at normal operating temperatures, and the fuel return line closed (if present). If pump
pressure is too low or too high install a new fuel pump.
3. Reconnect fuel line at filter and install air cleaner.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications
Idle Speed: Specifications
Curb Idle Speed ...................................................................................................................................
................................................ 650 rpm (in DRIVE)
Fast Idle Speed ...................................................................................................................................
........................................... 1600 rpm (in PARK) [1]
[1] On high step of fast idle cam.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure
Air Cleaner Housing: Technical Service Bulletins Air Cleaner - Sealing Procedure
Article No. 83-25-21-S
AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS
WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD
CONDITIONS ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED
LIGHT TRUCKS 1980-83 E, F AND BRONCO
This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the
TSB are of insufficient detail and are therefore being deleted from the TSB.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB.
See your normal parts listing for these part numbers.
The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing
concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles,
a poor running condition. The following procedure should minimize these concerns.
1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the
tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light
trucks except the 1983 Econoline with the 4.9L engine.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB.
See your normal parts listings for these part numbers.
2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that
would prevent a good seal. Replace any damaged components.
3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped
or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the
carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure
a tight bond.
Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A.
FIGURE 24
4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the
radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure
the zip tube to the top of the housing with a nylon tie-down
strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be
reinstalled to the radiator support. 5.
Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in
the air cleaner with an in-line filter.
a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in
the air cleaner, the adapter at the air cleaner and the adapter retaining clip.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 331
b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing
crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does
not need a new hole).
c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs.
2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L).
d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L
and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.).
NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking
into the end of the filter assembly.
e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S.
Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter
(closure) pack hole for 4.9L.
f. Cut the PCV filter (closure) hose to proper length and attach to the adapter.
g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only.
FIGURE 25
6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent
dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25).
a. Remove the carburetor from the vehicle.
b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or
equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the
carburetor. Pay particular attention to the top and bottom of the upper body casting around the
choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air.
c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body
casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper
motor at this time.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 332
FIGURE 24
d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a
toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning
"Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24).
Fill the hole completely around the rods from the top side only and release the throttle lever.
e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off"
position so that choke rod is fully raised. Fast idle cam should remain in "off" position.
f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft
rod. Fill the hole completely around the rod from the bottom side only.
g. Install the spring, pintle, gasket, and stepper motor.
h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV.
i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free)
accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper
body.
j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV
sealant should remain attached to upper body.
k. Re-install carburetor on vehicle.
7. Re-install and secure the air cleaner assembly as follows:
a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray
seating securely and completely sealing the flange.
b. Connect and secure the vacuum hoses.
c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for
4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L.
NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine.
d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing
nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing
to the carburetor is assured.
e. Connect the crankcase filter hose securely.
f. Install the heat riser tube. Connect the fresh air zip tube.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 333
Obtain an Authorized Modifications decal and list the date, dealer number and summary of
alterations performed. Select a prominent place adjacent to the Vehicle Emission Control
Information decal suitable for installing the Authorized Modifications decal. Clean the area, install
the decal and cover it with a clear plastic decal shield. PART NUMBER
PART NAME CLASS
E2AZ-6A768-A PCV Filter C
E2AZ-6853-A 1/2" PCV Hose C
E43Z-9E606-A Adapter C
E2TZ-9601-B Air Filter Element AM
E0TZ-9601-A Air Filter Element AM
C6TZ-9697-A Washer AM
D8ZZ-9654-A Gasket A
377678-S Plug BR
E3AZ-19562-A RTV Sealer A
390013-S36B Wing Nut S
C8DZ-9654-A Gasket AM
OTHER APPLICABLE ARTICLES: 83-25-21 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP9600C84 TIME:
6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start
Fuel Filter: Customer Interest Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start >
Page 342
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start >
Page 343
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start >
Page 344
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start
Fuel Filter: All Technical Service Bulletins Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 350
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 351
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 352
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 85610 > Mar > 85 > Fuel Filter Replacement Information
Fuel Filter: All 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Fuel Filter: > 85610 > Mar > 85 > Fuel Filter - Replacement
Information
Fuel Filter: All 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing
Connector > Component Information > Description and Operation
Ignition Timing Connector: Description and Operation
Fig. 20 Ignition Timing Vacuum Switch
Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition
module to retard spark timing. The switch is closed above the vacuum setting and the ignition
module is in the non-retard spark timing mode. Calibration resistors inside the switch control the
amount of retard.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing
Connector > Component Information > Description and Operation > Page 369
Ignition Timing Connector: Testing and Inspection
Ignition Timing Vacuum Switch
Ignition Timing Vacuum Switch Test Chart
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less
than'' values in the Ignition Timing vacuum Switch Test chart.
3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured
across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart.
4. Replace switch if resistance is not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and
Indicators > System Information > Diagrams
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Testing and Inspection
Ignition Cable: Testing and Inspection
Spark Plug Wire Resistance
*** UPDATED BY TSB #85-9-33
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Advance Unit > Component Information > Specifications
DISTRIBUTOR TIMING ADVANCE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism
Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism
The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly
is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm
assembly used depends on the engine calibration.
Single Diaphragm Assembly
SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the
armature to stator relationship to give spark advance. The stator assembly position is changed by
means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm
assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance
spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached
to the stator assembly, makes the the stator assembly move with respect to the armature. This
changes the initial armature to stator relationship set during initial timing, causing spark advance.
The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly,
is attached to the distributor base.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 382
Dual Diaphragm Assembly
DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in
the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum
advance port causes the advance diaphragm and attached rod to move, otherwise the action is the
same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard
diaphragm to move, compressing the retard spring, which controls the rate of spark retard.
Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by
the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm
rod moves causing the attached stator assembly to change position with respect to the armature. In
this instance the direction of the stator assembly movement is opposite that occurring during
vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port
overrides any spark retard caused by vacuum being applied to the retard port.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 383
Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism
Distributor - Exploded view
The centrifugal advance mechanism varies the relationship of the armature to the stator assembly.
The armature is mounted to the sleeve and plate assembly which rotates in relation to the
distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine
RPM. The movement of the weights change the initial relationship of the armature to the stator
assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor
shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by
calibrated springs.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Advance Unit > Component Information > Description and Operation > Page 384
Distributor Advance Unit: Service and Repair
1. Remove distributor cap and rotor.
2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup
assembly.
3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link.
4. Carefully remove unit from distributor.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Retard Control > Component Information > Locations
Distributor Retard Control: Locations
Below Vacuum Switch Between No. 5 & No. 6 Spark Plugs
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Vacuum Control > Component Information > Description and Operation
Distributor Vacuum Control: Description and Operation
3-Port Vacuum Regulator
Vacuum Regulator (3 & 4 Port)
Three port, Fig. 27, regulators and four port, Fig. 28, regulators are used to control the vacuum
advance to the distributor. During engine idle conditions, the manifold vacuum signal is reduced to
a constant output signal. Off idle, the output signal equals the spark port.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly
Distributor Vacuum Control: Testing and Inspection Distributor Modulator Valve Assembly
1. Turn ignition key to ``ON'' and check resistance at solenoid terminals.
2. If solenoid resistance is not 51---108 ohms, replace solenoid.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly > Page 393
Distributor Vacuum Control: Testing and Inspection Vacuum Regulator
Procedure
1. Disconnect vacuum line from distributor port and connect a vacuum gauge.
2. With engine at idle, the vacuum gauge reading should be within 1 inch Hg. vacuum of the
calibration point. The calibration point of each valve can
be identified according to color code as follows: Black, 6 inches Hg.; green, 7 inches Hg.; red, 8
inches Hg.
3. Replace valve if not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Plate W/ Pick-up Sensor > Component Information > Service and Repair
Distributor Plate W/ Pick-up Sensor: Service and Repair
1. Remove distributor cap and rotor.
2. Remove vacuum advance unit and magnetic pickup assembly.
3. Remove attaching screws and lift base plate from distributor.
4. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Spark
Delay Valve > Component Information > Description and Operation
Vacuum Spark Delay Valve: Description and Operation
Fig.25 - Spark Delay Valve
This unit is used in conjunction with some of the other Ford systems. Its purpose is to further
reduce emissions by delaying the spark advance during rapid acceleration and by cutting off
advance immediately upon deceleration. Fig. 25.
This plastic disc-shaped valve is installed in the carburetor vacuum line at the distributor advance
diaphragm. It is a one way valve and will not operate if installed backwards. The black side of the
valve must be toward the carburetor. This valve cannot be repaired.
NOTE: On all systems which employ the dual diaphragm distributor the line which has high vacuum
at idle (normal operating temperature) is
connected to the secondary (retard) side of the distributor vacuum advance unit. This is the
connection closest to the distributor cap.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Spark
Delay Valve > Component Information > Description and Operation > Page 400
Vacuum Spark Delay Valve: Testing and Inspection
Fig.36 - SDV Valve Color Coding
Fig.37 - Spark Delay Valve (SDV) Specifications Chart
Refer to Figs. 36 & 37 for number value by color code.
NOTE: To perform the following procedure, an external vacuum source capable of maintaining a
minimum constant 10 inches Hg. is required.
Mono Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect black side of delay valve to vacuum
source.
2. Connect a vacuum gauge with a 24 inch hose to colored side of delay valve.
3. Apply 10 inches Hg. vacuum and observe time in seconds for gauge to read 0-8 inches Hg. The
minimum and maximum time for gauge to read 8
inches Hg. should be as shown in Fig. 37.
Dual Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect vacuum gauge with a 24 inch hose to
DIST nipple of delay valve.
2. Connect black side of delay valve and CARB nipple of delay valve to vacuum source.
NOTE: Avoid applying vacuum to CARB nipple while applying vacuum to black side of valve.
3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches
Hg. The minimum and maximum time for gauge to
read 8 inches Hg. should be as shown in Fig. 37.
Retard Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect colored side of delay valve to vacuum
source.
2. Connect a vacuum gauge with a 24 inch hose to white side of delay valve.
3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches
Hg. The minimum and maximum time for gauge to
read 8 inches Hg. should be as shown in Fig. 37.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications
Spark Plug: Specifications
Spark Plugs 5-10 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
Compression Pressure Limit Chart
Compression pressures are considered within specification if the lowest reading cylinder is within
25 percent of the highest reading cylinder.
NOTE: Variations exceeding 25 percent indicate an improperly seated valve or worn/broken piston
rings.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 407
Compression Check: Testing and Inspection
1. Warm engine to normal operating temperature, then remove spark plugs and set throttle plates
to wide open position. 2. Install a suitable compression gauge in cylinder No. 1 spark plug hole. 3.
Install an auxiliary starter switch in the starting circuit. 4. With key off, using auxiliary starter switch,
crank engine at least five compression strokes and record highest reading. 5. Repeat test on each
cylinder. 6. Indicated compression pressures are within specification if the lowest reading cylinder
is within 25% of the highest reading.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
ENGINE YEAR CLEARANCE
V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165
V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150
On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications > Page 411
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications > Page 412
Valve Clearance: Adjustments
Fig. 21 Compressing valve lifter with tool to check clearance on engines with hydraulic valve lifters
V8 ENGINES To provide a means to compensate for dimensional changes in the valve train and
provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve
clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance
is more than the maximum, the longer pushrod should be used. To check the valve clearance,
proceed as follows:
1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of
compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one
quarter turn clockwise (90°) from position No. 2.
2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 1 Intake No. 1 Exhaust No. 7 Intake No. 5 Exhaust No. 8 Intake No. 4
Exhaust V8-351 & 400 No. 1 Intake No. 1 Exhaust No. 4 Intake No. 3 Exhaust No. 8 Intake No. 7
Exhaust
3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 5 Intake No. 2 Exhaust No. 4 Intake No. 6 Exhaust V8-351 & 400 No. 3
Intake No. 2 Exhaust No. 7 Intake No. 6 Exhaust
4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 2 Intake No. 7 Exhaust No. 3 Intake No. 3 Exhaust No. 6 Intake No. 8
Exhaust V8-351 & 400 No. 2 Intake No. 4 Exhaust No. 5 Intake No. 5 Exhaust No. 6 Intake No. 8
Exhaust
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications
Drive Belt: Specifications
A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used.
Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use
a strand tension gauge. Measurements are in pounds.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 416
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service
Bulletins > Air Cleaner - Sealing Procedure
Air Cleaner Housing: Technical Service Bulletins Air Cleaner - Sealing Procedure
Article No. 83-25-21-S
AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS
WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD
CONDITIONS ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED
LIGHT TRUCKS 1980-83 E, F AND BRONCO
This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the
TSB are of insufficient detail and are therefore being deleted from the TSB.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB.
See your normal parts listing for these part numbers.
The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing
concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles,
a poor running condition. The following procedure should minimize these concerns.
1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the
tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light
trucks except the 1983 Econoline with the 4.9L engine.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB.
See your normal parts listings for these part numbers.
2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that
would prevent a good seal. Replace any damaged components.
3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped
or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the
carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure
a tight bond.
Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A.
FIGURE 24
4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the
radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure
the zip tube to the top of the housing with a nylon tie-down
strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be
reinstalled to the radiator support. 5.
Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in
the air cleaner with an in-line filter.
a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in
the air cleaner, the adapter at the air cleaner and the adapter retaining clip.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service
Bulletins > Air Cleaner - Sealing Procedure > Page 422
b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing
crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does
not need a new hole).
c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs.
2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L).
d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L
and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.).
NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking
into the end of the filter assembly.
e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S.
Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter
(closure) pack hole for 4.9L.
f. Cut the PCV filter (closure) hose to proper length and attach to the adapter.
g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only.
FIGURE 25
6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent
dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25).
a. Remove the carburetor from the vehicle.
b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or
equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the
carburetor. Pay particular attention to the top and bottom of the upper body casting around the
choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air.
c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body
casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper
motor at this time.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service
Bulletins > Air Cleaner - Sealing Procedure > Page 423
FIGURE 24
d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a
toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning
"Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24).
Fill the hole completely around the rods from the top side only and release the throttle lever.
e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off"
position so that choke rod is fully raised. Fast idle cam should remain in "off" position.
f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft
rod. Fill the hole completely around the rod from the bottom side only.
g. Install the spring, pintle, gasket, and stepper motor.
h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV.
i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free)
accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper
body.
j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV
sealant should remain attached to upper body.
k. Re-install carburetor on vehicle.
7. Re-install and secure the air cleaner assembly as follows:
a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray
seating securely and completely sealing the flange.
b. Connect and secure the vacuum hoses.
c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for
4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L.
NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine.
d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing
nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing
to the carburetor is assured.
e. Connect the crankcase filter hose securely.
f. Install the heat riser tube. Connect the fresh air zip tube.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service
Bulletins > Air Cleaner - Sealing Procedure > Page 424
Obtain an Authorized Modifications decal and list the date, dealer number and summary of
alterations performed. Select a prominent place adjacent to the Vehicle Emission Control
Information decal suitable for installing the Authorized Modifications decal. Clean the area, install
the decal and cover it with a clear plastic decal shield. PART NUMBER
PART NAME CLASS
E2AZ-6A768-A PCV Filter C
E2AZ-6853-A 1/2" PCV Hose C
E43Z-9E606-A Adapter C
E2TZ-9601-B Air Filter Element AM
E0TZ-9601-A Air Filter Element AM
C6TZ-9697-A Washer AM
D8ZZ-9654-A Gasket A
377678-S Plug BR
E3AZ-19562-A RTV Sealer A
390013-S36B Wing Nut S
C8DZ-9654-A Gasket AM
OTHER APPLICABLE ARTICLES: 83-25-21 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP9600C84 TIME:
6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Air Injection Filter > Component Information > Service and Repair
Air Injection Filter: Service and Repair
Fig. 68 Removing centrifugal type air pump filter
Centrifugal Filter Fan, Replace
1. Remove drive pulley and outer disc from air pump.
2. Remove filter fan from pump, Fig. 90.
NOTE: Do not attempt to remove the metal drive hub.
3. Install new filter fan using the pulley and bolts. Alternately tighten bolts to draw fan down evenly.
NOTE: A slight interference between the fan and housing is normal. A new fan may make noise
during initial operation, until it's outer diameter sealing lip has worn in, after approximately 20-30
miles of operation.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins >
Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start
Fuel Filter: Customer Interest Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins >
Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 436
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins >
Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 437
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins >
Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 438
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start
Fuel Filter: All Technical Service Bulletins Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 444
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 445
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 446
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fuel Filter: > 85610 > Mar > 85 > Fuel Filter - Replacement Information
Fuel Filter: All 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Fuel Filter: > 85610 > Mar > 85 > Fuel Filter - Replacement Information
Fuel Filter: All 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins
> Oil Filter - Heavy Duty Motorcraft Filter Now Available
Oil Filter: Technical Service Bulletins Oil Filter - Heavy Duty Motorcraft Filter Now Available
Article No. 86-25-17
OIL FILTER - 7.5L ENGINE - HEAVY DUTY MOTORCRAFT FILTER NOW AVAILABLE
LIGHT TRUCK 1974-87 E-250/350, F-250/350
A heavy duty Motorcraft oil filter (FL-1 HP) is now available for use on the 7.5L engine. It is
recommended that vehicles subject to severe service, as outlined in the Owner Guide or off-road
driving, use Motorcraft Oil Filter (FL-1 HP) at all normal oil change intervals.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins
> A/C - Filtering Refrigerant After Compressor Replacement
Technical Service Bulletin # 98-12-5 Date: 980622
A/C - Filtering Refrigerant After Compressor Replacement
Article No. 98-12-5
06/22/98
AIR CONDITIONING - FILTERING REFRIGERANT
AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS
FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS
1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86
CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92
MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII
1995-98-MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150,
F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98
EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER
1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to revise the Service Procedure and to update
the model years.
ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the
refrigerant system cleaned to remove any debris or contaminants that may be present to prevent
damage to the replacement compressor.
ACTION
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins
> A/C - Filtering Refrigerant After Compressor Replacement > Page 464
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins
> A/C - Filtering Refrigerant After Compressor Replacement > Page 465
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins
> A/C - Filtering Refrigerant After Compressor Replacement > Page 466
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Hoses > System Information > Service Precautions
Hoses: Service Precautions
SERVICE PRECAUTIONS
To prevent vehicle damage, always observe the following precautions: After servicing a hose, check for leaks before and after test driving the vehicle.
- Always use the correct size hose. Do not use standard sized hose in place of metric hose or vice
versa.
Always use the correct type of hose. Never use vacuum hose in place of fuel hose. Never use
heater hose in place of PCV hose.
- When replacing hoses which are attached to the engine on one end and the frame or body on the
other end, always leave sufficient length to compensate for engine movement (from torque).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Recycled Engine Coolant - Service Tips
Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips
Article No. 95-18-2
09/11/95
^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP
^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP
FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT
1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE
1994 and after ASPIRE 1995 and after CONTOUR
LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN
CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE
1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and
after MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after
BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and
after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after
WINDSTAR
This TSB is being republished in its entirety to include warranty information when using recycled
coolant
ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly
processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda
Coolant Recycler (181-00003) process is the only approved coolant recycling method available
through Ford that is capable of producing recycled engine coolant that meets Ford specification
ESE-M97B44-A.
ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using
Rotunda Coolant Recycler (181-00003).
NOTE:
WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE
PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED
FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY
AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND
LABELING CONCERNS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Recycled Engine Coolant - Service Tips > Page 475
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Recycled Engine Coolant - Service Tips > Page 476
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Coolant Capacity 28 qts
..............................................................................................................................................................
..........................................
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 479
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 861117 > Jun > 86 > A/T - Synthetic Fluid Availability
Fluid - A/T: Customer Interest A/T - Synthetic Fluid Availability
Article No. 86-11-17
TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC
TRANSMISSION FLUID
FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986
TAURUS
LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR,
CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE
LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER
A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part
number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a
wider range of temperatures.
In the event a vehicle will be operated in extremely cold temperatures for an extended period of
time, remove all existing fluid from the transmission (using the procedure shown in the applicable
1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid,
E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer
weather.
CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid.
PART NUMBER PART NAME CLASS
E6AZ-19582-B Synthetic Dexron Oil V
Automatic Transmission Oil
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage
Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage
TSB 06-14-4
07/24/06
MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID.
FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993
Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996
Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996
Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004
Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650,
F-750
LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator
2002-2003 Blackwood
MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer
1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner
MERKUR: 1985-1989 XR4TI
This article supersedes TSB 01-15-7 to update the vehicle application chart.
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid.
ACTION Beginning immediately all automatic transmission / transaxle applications requiring
MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission
Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R)
Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will
only continue for however long it takes to deplete what remains in inventory.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 493
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 494
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid
Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid
TRANSMISSION - AUTOMATIC/MANUAL - Article No.
NEW FLUID AND USAGE CHART 87-18-14
FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS,
THUNDERBIRD, FORD
LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior
TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II,
AEROSTAR
ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart),
(XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON"
transmission fluid, where specified, will improve cold weather shift effort and synchronized
operation.
ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic
transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles.
NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual
transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the
transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent.
PART NUMBER PART NAME CLASS
XT-2-QDX MERCON - Quart V
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid > Page 499
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fluid - A/T: > 861117 > Jun > 86 > A/T - Synthetic Fluid Availability
Fluid - A/T: All Technical Service Bulletins A/T - Synthetic Fluid Availability
Article No. 86-11-17
TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC
TRANSMISSION FLUID
FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986
TAURUS
LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR,
CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE
LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER
A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part
number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a
wider range of temperatures.
In the event a vehicle will be operated in extremely cold temperatures for an extended period of
time, remove all existing fluid from the transmission (using the procedure shown in the applicable
1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid,
E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer
weather.
CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid.
PART NUMBER PART NAME CLASS
E6AZ-19582-B Synthetic Dexron Oil V
Automatic Transmission Oil
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage
Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage
TSB 06-14-4
07/24/06
MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID.
FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993
Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996
Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996
Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004
Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650,
F-750
LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator
2002-2003 Blackwood
MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer
1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner
MERKUR: 1985-1989 XR4TI
This article supersedes TSB 01-15-7 to update the vehicle application chart.
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid.
ACTION Beginning immediately all automatic transmission / transaxle applications requiring
MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission
Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R)
Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will
only continue for however long it takes to deplete what remains in inventory.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 509
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 510
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid
Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid
TRANSMISSION - AUTOMATIC/MANUAL - Article No.
NEW FLUID AND USAGE CHART 87-18-14
FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS,
THUNDERBIRD, FORD
LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior
TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II,
AEROSTAR
ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart),
(XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON"
transmission fluid, where specified, will improve cold weather shift effort and synchronized
operation.
ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic
transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles.
NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual
transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the
transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent.
PART NUMBER PART NAME CLASS
XT-2-QDX MERCON - Quart V
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid > Page 515
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity
Fluid - A/T: Specifications
Type MERCON(R) Automatic Transmission Fluid
CAPACITY, Initial Refill*: C-6 5.0 qt (US)
With the engine at operating temperature, shift
transmission through all gears. Check fluid level in PARK
and add fluid as needed
Others 3.0 qt (US)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity >
Page 518
Fluid - A/T: Specifications
Type MA(MERCON (R) Automatic Transmission Fluid)
CAPACITY, Total Fill: Tempo, Topaz 8.3 qt (US)
Others 9.8 qt (US)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Drivetrain - Lubricant Usage
Fluid - M/T: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Drivetrain - Lubricant Usage > Page 523
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Drivetrain - Lubricant Usage > Page 524
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Drivetrain - Lubricant Usage > Page 525
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Page 526
Fluid - M/T: Specifications
TYPE 80W EP
CAPACITY, Refill: 3-speed 3.5 pt (US)
4-speed ex. OD 7.0 pt (US)
W/OD 4.5 pt (US)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service
Bulletins > Drivetrain - Lubricant Usage
Fluid - Differential: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service
Bulletins > Drivetrain - Lubricant Usage > Page 531
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service
Bulletins > Drivetrain - Lubricant Usage > Page 532
Fluid - Differential: Technical Service Bulletins Front/Rear Drive Axles - Lubricant Drain/Fill
Procedure
Article No. 83-3-23
FRONT AND REAR DRIVE AXLES - LUBRICANT DRAIN AND FILL PROCEDURE
LIGHT TRUCKS 1979-83 F100-350, BRONCO, E100-350, RANGER, BRONCO II
The following is the recommended procedure for draining axle lubricant from front and/or rear
driving axles on all light truck models.
1. Drive the vehicle for 10-15 miles at highway speed to warm axle lubricant to operating
temperature and minimum viscosity.
2. Raise the vehicle on a hoist and place a drain pan under the axle to be drained.
3. Wire brush the filler plug area of the axle housing cover or carrier assembly to prevent possible
entry of dirt, rust, etc. into the axle assembly.
4. Remove the axle lubricant fill plug.
5. Using a suitable suction-type utility pump (manual or powered), drain the axle lubricant from the
axle by inserting the pump suction hose through axle filler plug hole down into the lowest portion of
the axle carrier housing removing all the lubricant.
6. Fill the axle housing with the specified amount and type of lubricant as shown on the following
specification charts.
7. Install the filler plug and torque as shown on the following specification charts.
FRONT/REAR DRIVING AXLE SPECIFICATION CHARTS
I. Filler Rug Torque Chart
Axle Fill Plug Torque All Dana Front/Rear 20-30 Ft.Lbs.
- Ford Built Rear Axles 25-50 Ft.Lbs.
II. Axle Lubricant Capacities - Econoline
Approximate Capacity (1) U.S. Pints (2) Ford Standard and Traction-Lok
5.5 (3)
(E-100/150)
Dana Standard and Limited Slip 6.0 (4)
(E-250, Model 60/61-2)
Dana Standard and Limited Slip 6.5 (4)
(Model 70), Dual Rear Wheels
Ford Standard and Traction-Lok 5.5
(E-250 Van)
Dana Standard and Limited Slip 6.0 (4)
(Model 61-1) Single Rear Wheels
(1) Service refill capacities are determined by filling to the bottom of the filler hole.
(2) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A All Dana Conventional and Limited-Slip Rear Axles - Use ESW-M2C105-A
(3) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford
TractionLok axle.
(4) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana
Rear Limited-Slip Axle.
III. Axle Lubricant Capacities - Bronco Chart
Approximate Capacity (1) U.S. Pints Front Axle (5) Dana
3.8 (3)
Rear Axle (4) Ford 5.5 (2)
(1) Refill Capacity is determined by filling to the bottom of the filler hole.
(2) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A.
(3) All Dana Conventional and Limited-Slip Front Drive
Axles - Use ESW-M2C105-A.
(4) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford
TractionLok Axle (1979-1982).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service
Bulletins > Drivetrain - Lubricant Usage > Page 533
(5) Add 2 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana
Front Limited-Slip Axle.
IV. Axle Lubricant Capacities - F100 - F350 (4x2/4x4)
Approximate Capacity (1) U.S. Measure Axle Model (4)
Truck Type (Pints)
Ford 8.8" and 9" F100/150/250 5.5 (3)
Dana 44-IFS (Front Axle) F150/250 (4x4) 3.8
Dana 60 (Rear) F250 6.0
Dana 61-2 (Rear) F250 6.0
Dana 50-IFS (Front Axle) F250/350 (4x4) Heavy 4.1
Duty & Snow Plow
Dana 70 (Rear) F350 DRW Chassis Cab 6.5
Dana 70 HD (Rear) F350 DRW Regular Cab 7.4
Dana 61-1 (Rear F250/350 SRW 6.0
(1) Service refill capacities are determined by filling to the
bottom of the filler hole.
(2) Add EST-M2C118-A (Friction Modifier Part No. C8AZ-19B546-A) for complete refill of Dana
LimitedSlip axles. Add 4 ounces for F250/350 Rear. For F150 & F250 4x4 add 2 ounces to front
axle.
(3) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford
TractionLok Axle (1979-1982).
(4) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A. All Dana Conventional and Limited-Slip Front/Rear Axles - Use
ESW-M2C105-A.
V. Axle Lubricant Capacities - Ranger 4x2/4x4, Bronco II
Approximate Capacities
U.S. Imperial
Measure Measure
(Pints) (Pints) Liters
Rear Ford 6-3/4 Ring Gear (1)(4) 3.0 2.5 1.4
Rear Ford 7.5 Ring Gear (2)(4) 5.0 (6) 4.2 2.4
Dana 28 Front Axle (4x4 Only)(3)(5) 1.0 (7) 0.83 0.45
Bronco II Ford 7.5 Ring Gear(2)(4) 5.5 (6) 4.6 2.6
(1) Fill to 3/8 in. +/- 1/8 in. (9.5 mm +/- 3 mm) below bottom of fill hole. Base GVW axle with 2.0L
engine and 2.3L engine with automatic.
(2) Fill to 1/2 in. +/- 1/8 in. (12.7 mm t 3 mm) below bottom of fill hole. Optional GVW or 2.3L
engine.
(3) Fill to 1/2 in. +/- 1/8 in. (12.7 mm + 3 mm) below bottom of fill hole.
(4) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A.
(5) All Dana Conventional and Limited-Slip Front Axles - Use ESW-M2C105-A.
(6) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford
TractionLok Axle.
(7) Add 1/2 ounce of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana
Front Limited-Slip Axle.
PART NUMBER PART NAME CLASS
E0AZ-19580-A Lubricant-ESP-M2C154-A AM
C6AZ-19580-E Lubricant-ESW-M2C105-A AG
C8AZ-19B546-A Friction Modifier-EST-M2C118-A A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications
Fluid - Differential: Capacity Specifications
TYPE: Standard 90 HP
Limited-Slip 90 HP*
CAPACITY, Refill: Front: All models 4.0 pt (US)
LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Letter &
number on plate on door lock pillar
Rear: Dana 60 5.0 pt (US)
Dana 61 6.0 pt (US)
1982 70 HD 7.4 pt (US)
1981 Econoline w/Dana 70 7.0 pt (US)
Others 6.5 pt (US)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications > Page 536
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service
Bulletins > Drivetrain - Lubricant Usage
Fluid - Transfer Case: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service
Bulletins > Drivetrain - Lubricant Usage > Page 541
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
TYPE MERCON(R) Automatic Transmission Fluid
CAPACITY, Refill: NP208 7.0 pt (US)
Warner 1345 6.5 pt (US)
Warner 1350 Ranger 3.0 pt (US)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 544
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine - Oil Level Checking Procedure
Engine Oil: Technical Service Bulletins Engine - Oil Level Checking Procedure
Article No. 85-25-20
OIL DIPSTICK - ENGINE OIL LEVEL CHECKING PROCEDURE - GASOLINE ENGINES
LIGHT TRUCK 1986 AND PRIOR
MEDIUM/HEAVY TRUCK 1986 AND PRIOR
Figure 17 - Dipstick
To correctly check the engine oil level, the vehicle must be parked on a level surface. Allow a few
minutes after shutting the engine off for oil to drain down before checking. For consistent oil level
readings, insert the dipstick with the loop of the handle as shown in Figure 17.
Figure 18 - Dipstick - Calibration
Figure 19 - Dipstick - Calibration
Dipsticks in Ford vehicles do not incorporate a Full mark. Instead, the dipstick will have marks
indicating a Safe range and an Add range as shown in Figure 18 or 19. When the correct amount
of oil is in the engine, the oil level indication will be in the Safe range or above the Minimum mark,
but not necessarily at the top of the Safe range or at the Maximum mark.
When the indicated oil level is in the Add range put one quart of oil in the engine. Recheck the oil
level to determine if the oil level is now in the Safe range or above the Minimum mark.
Add and recheck oil level one quart at a time until the oil level indicator moves into the Safe range
or above the Minimum mark. Do not add additional oil to bring the level to the top of the Safe range
or to the Maximum mark since this may result in overfill and increased oil consumption. If the
accuracy of the engine oil dipstick is in doubt, it may be verified in the following manner:
^ Drain the oil and install a new filter.
^ Put in the specified amount of oil for an oil and filter change. (See owner guide)
^ Start the engine and operate a few minutes.
^ Shut off the engine and allow a few minutes for the oil to drain down.
^ Check the oil level with the dipstick.
^ If the oil level does not indicate in the Safe range or above the Minimum mark, rework or replace
the dipstick.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine oil capacity ...............................................................................................................................
........................................................... 5.0 Qts.(4.7L)
Note: Add 1 Qt. with filter change.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 551
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Filtering Refrigerant After Compressor Replacement
Technical Service Bulletin # 98-12-5 Date: 980622
A/C - Filtering Refrigerant After Compressor Replacement
Article No. 98-12-5
06/22/98
AIR CONDITIONING - FILTERING REFRIGERANT
AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS
FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS
1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86
CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92
MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII
1995-98-MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150,
F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98
EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER
1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to revise the Service Procedure and to update
the model years.
ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the
refrigerant system cleaned to remove any debris or contaminants that may be present to prevent
damage to the replacement compressor.
ACTION
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Filtering Refrigerant After Compressor Replacement > Page 556
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Filtering Refrigerant After Compressor Replacement > Page 557
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Filtering Refrigerant After Compressor Replacement > Page 558
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Filtering Refrigerant After Compressor Replacement > Page 559
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Filtering Refrigerant After Compressor Replacement > Page 560
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Filtering Refrigerant After Compressor Replacement > Page 561
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Filtering Refrigerant After Compressor Replacement > Page 562
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Filtering Refrigerant After Compressor Replacement > Page 563
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Filtering Refrigerant After Compressor Replacement > Page 564
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Without Rear A/C .................................................................................................................................
....................................................................... 3.5 lbs
With Rear A/C ......................................................................................................................................
..................................................................... 4.25 lbs
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 567
Refrigerant: Fluid Type Specifications
Type .....................................................................................................................................................
............................................... Refrigerant 12 (R-12) Ford Part Number .............................................
........................................................................................................................................
D4AZ-19B519-A
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Refrigerant Oil System Capacity .........................................................................................................
....................................................................... 10.5 oz
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 572
Refrigerant Oil: Fluid Type Specifications
Compressor ................................................................................................................... 500 viscosity
(C9AZ-19557-B or Motorcraft VN-2 or equivalent)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair
Brake Bleeding: Service and Repair
Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on
each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has
been drained from hydraulic system.
1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to
absorb escaping brake fluid.
2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at
fitting.
3. Hold pedal down and tighten fittings, then release brake pedal. Releasing brake pedal before
fittings are tightened will allow air to enter the master cylinder.
4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm.
5. Bleed rear brakes as follows:
a. Pump pedal several times, then hold pedal down firmly. b. With pedal firmly depressed, open
bleeder screw on one rear brake until pedal fades to floor, then close bleeder valve. c. Repeat
procedure until a continuous flow of brake fluid is released from bleeder valve. d. Repeat steps 5a
through 5c on other rear brake.
6. Bleed front brakes using same procedure as for rear brakes.
7. Fill master cylinder reservoirs to {1/4} inch from top of reservoirs.
8. Centralize the pressure differential control valve, if applicable, as follows:
a. Turn ignition switch to ``ACC'' or ``On'' position. b. Push brake pedal down, allowing piston to
center itself, turning off warning light. c. Turn ignition switch to ``OFF'' position.
9. Check brake operation and ensure pedal is firm, then road test vehicle.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative
Fuse: Customer Interest A/C Blower Motor - Inoperative
Article No. 85-10-19
AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER
LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES
When operating the A/C system for long periods of time with the blower motor set on high, the
solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the
heat build-up. A revised fuse holder is released to resolve the subject concern.
The following procedure should be performed:
1. Check fuse for damage (solder melted at end of fuse).
2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat
build-up).
3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for
inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in
Steps 1 and 2 continue with Step 4.
4. Disconnect battery ground cable.
5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel.
6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close
to the fuse panel as possible and remove the fuse holders from the fuse panel.
7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 585
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative
Fuse: All Technical Service Bulletins A/C Blower Motor - Inoperative
Article No. 85-10-19
AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER
LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES
When operating the A/C system for long periods of time with the blower motor set on high, the
solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the
heat build-up. A revised fuse holder is released to resolve the subject concern.
The following procedure should be performed:
1. Check fuse for damage (solder melted at end of fuse).
2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat
build-up).
3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for
inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in
Steps 1 and 2 continue with Step 4.
4. Disconnect battery ground cable.
5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel.
6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close
to the fuse panel as possible and remove the fuse holders from the fuse panel.
7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page
591
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > Page 592
Fuse: Locations
LH Shroud, Near Access Hole
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations
> Fuse Link B
Fusible Link: Locations Fuse Link B
Attached To Auxiliary Battery Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations
> Fuse Link B > Page 597
Fusible Link: Locations Fuse Link C
Attached To Junction Block Or Auxiliary Battery Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations
> Fuse Link B > Page 598
Fusible Link: Locations Fuse Link D
Attached To Junction Block Or Auxiliary Battery Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations
> Fuse Link B > Page 599
Fusible Link: Locations Fuse Link E
At Starter Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations
> Fuse Link B > Page 600
Fusible Link: Locations
Fuse Link B
Attached To Auxiliary Battery Relay
Fuse Link C
Attached To Junction Block Or Auxiliary Battery Relay
Fuse Link D
Attached To Junction Block Or Auxiliary Battery Relay
Fuse Link E
At Starter Relay
Fuse Link G
At Starter Relay
Fuse Link K
At Junction Block
Fuse Link L
Connected To Junction Block Or Auxiliary Battery Relay
Fuse Link M
At Starter Relay
Fuse Links A, G & H
Attached To Starter Motor Relay
Fuse Links G & H ( W/Ammeter)
In Harness, RH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > System Information > Service Precautions
Service Reminder Indicators: Service Precautions
SERVICE PRECAUTION
All Service Reminder Indicators should be investigated or serviced immediately. Vehicle damage
may result if the indicator is ignored.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear
Tires: Customer Interest Tires - Front Outside Edge Wear
Article No. 85-19-16
TIRE WEAR - FRONT - OUTSIDE EDGE
LIGHT TRUCK 1976-86 E100-150
Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by
excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15
can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit
contains complete instructions for modifying the front radius arms and mounting a metal adjusting
cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch
along two sides of the cam to the lower flange of the radius arm.
Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5
degrees. Increasing caster more than 3 degrees is not recommended since this may cause
complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased
on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built
into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of
each axle.
Three other significant factors may also contribute to outboard shoulder wear. They are excessive
toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After
any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to
extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life.
PART NUMBER PART NAME CLASS
E5TZ-3K064-A Kit Caster Adjustment C
OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME:
4.6 Hrs.
OPERATION: 3001A TIME:
0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear
Tires: All Technical Service Bulletins Tires - Front Outside Edge Wear
Article No. 85-19-16
TIRE WEAR - FRONT - OUTSIDE EDGE
LIGHT TRUCK 1976-86 E100-150
Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by
excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15
can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit
contains complete instructions for modifying the front radius arms and mounting a metal adjusting
cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch
along two sides of the cam to the lower flange of the radius arm.
Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5
degrees. Increasing caster more than 3 degrees is not recommended since this may cause
complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased
on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built
into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of
each axle.
Three other significant factors may also contribute to outboard shoulder wear. They are excessive
toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After
any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to
extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life.
PART NUMBER PART NAME CLASS
E5TZ-3K064-A Kit Caster Adjustment C
OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME:
4.6 Hrs.
OPERATION: 3001A TIME:
0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 841919 > Sep > 84 > Steering - Pull/Drift Diagnostic Procedures
Tires: All Technical Service Bulletins Steering - Pull/Drift Diagnostic Procedures
Article No. 84-19-19
STEERING PULL/DRIFT/ROADABILITY - DIAGNOSTIC PROCEDURES
LIGHT TRUCKS 1980-84 F100-350, BRONCO, ECONOLINE
Section 19 of the 1983 and 1984 Light Truck Shop Manuals provides procedures to resolve most
roadability concerns experienced to date. These procedures can be applied to any 1980 and later
model light trucks.
When servicing 4 wheel drive vehicles with limited slip front axles, front tire circumference is the
most probable cause if the pull is only present when the hubs are locked. Installing the two most
evenly matched tires on the front axle should resolve the concern.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 841919 > Sep > 84 > Steering - Pull/Drift Diagnostic Procedures
Tires: All Technical Service Bulletins Steering - Pull/Drift Diagnostic Procedures
Article No. 84-19-19
STEERING PULL/DRIFT/ROADABILITY - DIAGNOSTIC PROCEDURES
LIGHT TRUCKS 1980-84 F100-350, BRONCO, ECONOLINE
Section 19 of the 1983 and 1984 Light Truck Shop Manuals provides procedures to resolve most
roadability concerns experienced to date. These procedures can be applied to any 1980 and later
model light trucks.
When servicing 4 wheel drive vehicles with limited slip front axles, front tire circumference is the
most probable cause if the pull is only present when the hubs are locked. Installing the two most
evenly matched tires on the front axle should resolve the concern.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments
Wheel Bearing: Adjustments
EXCEPT 4 WHEEL DRIVE MODELS
1. Remove wheel and tire assembly, disc brake caliper and pads, dust cap, locknut, adjusting nut,
washer and cotter pin.
2. Tighten wheel adjusting nut to 22-25 ft. lbs. while rotating disc brake rotor in opposite direction.
3. Back off wheel retention nut 1/8 turn and install retainer and cotter pin without any additional
movement of nut.
4. Reinstall dust cap, caliper, pads and tire and wheel assembly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments >
Page 630
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical
Service Bulletins > Recalls for Axle Nut: > NHTSA82V104000 > Oct > 82 > recall 82V104000: Rear Axle Nut Inspection
Axle Nut: Recalls recall 82V104000: Rear Axle Nut Inspection
ON CERTAIN VEHICLES, THE LOCK WEDGES USED TO SECURE THE AXLE BEARING NUTS
TO THE AXLE HOUSING MAY FALL OUT OF POSITION, ALLOWING THE NUT TO LOOSEN.
THE NUT ON THE LEFT SIDE MAY FALL OFF, ALLOWING MOVEMENT OF THE AXLE SHAFT.
THE DEALER WILL REPLACE DEFECTIVE LOCK WEDGES WITH AN IMPROVED VERSION.
WHEEL BEARINGS WILL BE INSPECTED AND ADJUSTED OR REPLACED, IF NECESSARY.
VEHICLE DESCRIPTION: LIGHT TRUCKS WITH DANA FULL-FLOATING REAR AXLES.
SYSTEM: POWER TRAIN; REAR AXLE ASSEMBLY. CONSEQUENCES OF DEFECT: THIS
COULD RESULT IN PARTIAL LOSS OF BRAKING ACTION OR PARTIAL OR TOTAL
SEPARATION OF THE LEFT REAR WHEEL AND BRAKE ASSEMBLY.IN EITHER CASE, LOSS
OF VEHICLE CONTROL AND AN ACCIDENT COULD FOLLOW.
1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK F250 1982 FORD
TRUCK F350 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK F250
1983 FORD TRUCK F350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Axle Nut: > NHTSA82V104000 > Oct > 82 > recall 82V104000: Rear
Axle Nut Inspection
Axle Nut: All Technical Service Bulletins recall 82V104000: Rear Axle Nut Inspection
ON CERTAIN VEHICLES, THE LOCK WEDGES USED TO SECURE THE AXLE BEARING NUTS
TO THE AXLE HOUSING MAY FALL OUT OF POSITION, ALLOWING THE NUT TO LOOSEN.
THE NUT ON THE LEFT SIDE MAY FALL OFF, ALLOWING MOVEMENT OF THE AXLE SHAFT.
THE DEALER WILL REPLACE DEFECTIVE LOCK WEDGES WITH AN IMPROVED VERSION.
WHEEL BEARINGS WILL BE INSPECTED AND ADJUSTED OR REPLACED, IF NECESSARY.
VEHICLE DESCRIPTION: LIGHT TRUCKS WITH DANA FULL-FLOATING REAR AXLES.
SYSTEM: POWER TRAIN; REAR AXLE ASSEMBLY. CONSEQUENCES OF DEFECT: THIS
COULD RESULT IN PARTIAL LOSS OF BRAKING ACTION OR PARTIAL OR TOTAL
SEPARATION OF THE LEFT REAR WHEEL AND BRAKE ASSEMBLY.IN EITHER CASE, LOSS
OF VEHICLE CONTROL AND AN ACCIDENT COULD FOLLOW.
1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK F250 1982 FORD
TRUCK F350 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK F250
1983 FORD TRUCK F350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure
Wheel Fastener: Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure
Article No. 98-5A-4
^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP
^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP
FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA
1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97
PROBE 1994-97 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI
1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII
1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI
1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE
LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO
II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER
1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR
ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or
unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and
installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly
torqued wheel lug nuts may cause:
^ Brake vibration
^ Distortion of the wheel hub
^ Distortion of the brake rotor
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 649
^ 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 650
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
Compression Pressure Limit Chart
Compression pressures are considered within specification if the lowest reading cylinder is within
25 percent of the highest reading cylinder.
NOTE: Variations exceeding 25 percent indicate an improperly seated valve or worn/broken piston
rings.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 656
Compression Check: Testing and Inspection
1. Warm engine to normal operating temperature, then remove spark plugs and set throttle plates
to wide open position. 2. Install a suitable compression gauge in cylinder No. 1 spark plug hole. 3.
Install an auxiliary starter switch in the starting circuit. 4. With key off, using auxiliary starter switch,
crank engine at least five compression strokes and record highest reading. 5. Repeat test on each
cylinder. 6. Indicated compression pressures are within specification if the lowest reading cylinder
is within 25% of the highest reading.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications
Camshaft: Specifications
Camshaft Journal Diameter 2.1238-2.1248 in
Camshaft Bearing Inside Diameter 2.1258-2.1268 in
Camshaft Bearing Clearance .001-.003 in
Note: Service Limit -- 0.006 in
Camshaft End Play .001-.006 in
Note: Service Limit -- 0.009 in
Camshaft Runout Max. 0.005 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications > Page 661
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications
Lifter / Lash Adjuster: Specifications
Lifter Bore Diameter .8752-.8767 in
Lifter Diameter .8740-.8745 in
Lifter To Bore Clearance .0007-.0027 in
Note: Service Limit -- 0.005 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications > Page 665
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Arm To Cylinder Head Bolts 18-25 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 669
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications
Connecting Rod: Specifications
Connecting Rod Cap Bolts 40-45 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 674
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 675
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications Main Cap Torque
Main Cap Torque
Main Bearing Cap Bolts 95- 105 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Pulley 70-90 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Piston Diameter coded red 4.3585 - 4.3591 in
coded blue 4.3597 - 4.3603 in
Piston Clearance .0022-.0030 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications > Page 685
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications > Page 686
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Piston Pin Diameter 1.0398-1.0403 in
Pin to Piston Bore Clearance .0002-.0004 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Piston Ring End Gap, Comp. 0.01 in
Piston Ring End Gap, Oil 0.01 in
Piston Ring Side Clearance, Comp. .0025-.0045 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
ENGINE YEAR CLEARANCE
V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165
V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150
On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications > Page 697
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications > Page 698
Valve Clearance: Adjustments
Fig. 21 Compressing valve lifter with tool to check clearance on engines with hydraulic valve lifters
V8 ENGINES To provide a means to compensate for dimensional changes in the valve train and
provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve
clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance
is more than the maximum, the longer pushrod should be used. To check the valve clearance,
proceed as follows:
1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of
compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one
quarter turn clockwise (90°) from position No. 2.
2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 1 Intake No. 1 Exhaust No. 7 Intake No. 5 Exhaust No. 8 Intake No. 4
Exhaust V8-351 & 400 No. 1 Intake No. 1 Exhaust No. 4 Intake No. 3 Exhaust No. 8 Intake No. 7
Exhaust
3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 5 Intake No. 2 Exhaust No. 4 Intake No. 6 Exhaust V8-351 & 400 No. 3
Intake No. 2 Exhaust No. 7 Intake No. 6 Exhaust
4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 2 Intake No. 7 Exhaust No. 3 Intake No. 3 Exhaust No. 6 Intake No. 8
Exhaust V8-351 & 400 No. 2 Intake No. 4 Exhaust No. 5 Intake No. 5 Exhaust No. 6 Intake No. 8
Exhaust
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Arm To Cylinder Head Bolts 18-25 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 702
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Specifications
Valve Cover: Specifications
Rocker Arm Cover 5-6 ft/lb ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Specifications
Valve Guide: Specifications
Guide, Inside Diameter .3433-.3443 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Specifications > Page 709
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications
Valve Seat: Specifications
Seat Width, Intake .060-.080 in
Seat Width, Exhaust .060-.080 in
Runout 0.002 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 2.06 in
Out Of Square Limit 0.078 in
Installed Height Intake 1.797-1.828 in
Installed Height Exhaust 1.797-1.828 in
Spring Pressure, Closed, Intake 76-84 lbf at 1.81 in
Spring Pressure, Closed, Exhaust 76-84 lbf at 1.81 in
Spring Pressure, Open, Intake 218-240 lbf at 1.33 in
Spring Pressure, Open, Exhaust 218-240 lbf at 1.33 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications
Valve: Specifications
Stem Diameter Intake .3416-.3423 in
Stem Diameter Exhaust .3411-.3418 in
Maximum Tip Refinish 0.01 in
Face Angle 44 deg
Margin Intake 1/32 in
Margin Exhaust 1/32 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Specifications
Drive Belt: Specifications
A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used.
Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use
a strand tension gauge. Measurements are in pounds.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Specifications > Page 723
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair
Engine Mount: Service and Repair
Fig. 10 Engine mounts. V8-460 engine
V8-460
1. Support engine using a block of wood placed under oil pan and a suitable jack.
2. Remove locknuts from support bracket-to-crossmember and side rail attaching bolts.
3. Remove support bracket-to-insulator through bolts, Fig. 10.
4. Raise engine until insulator clears bracket, then remove insulator and bracket as an assembly.
5. Remove insulator-to-bracket attaching nuts and the insulator.
6. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - Oil Level Checking Procedure
Engine Oil: Technical Service Bulletins Engine - Oil Level Checking Procedure
Article No. 85-25-20
OIL DIPSTICK - ENGINE OIL LEVEL CHECKING PROCEDURE - GASOLINE ENGINES
LIGHT TRUCK 1986 AND PRIOR
MEDIUM/HEAVY TRUCK 1986 AND PRIOR
Figure 17 - Dipstick
To correctly check the engine oil level, the vehicle must be parked on a level surface. Allow a few
minutes after shutting the engine off for oil to drain down before checking. For consistent oil level
readings, insert the dipstick with the loop of the handle as shown in Figure 17.
Figure 18 - Dipstick - Calibration
Figure 19 - Dipstick - Calibration
Dipsticks in Ford vehicles do not incorporate a Full mark. Instead, the dipstick will have marks
indicating a Safe range and an Add range as shown in Figure 18 or 19. When the correct amount
of oil is in the engine, the oil level indication will be in the Safe range or above the Minimum mark,
but not necessarily at the top of the Safe range or at the Maximum mark.
When the indicated oil level is in the Add range put one quart of oil in the engine. Recheck the oil
level to determine if the oil level is now in the Safe range or above the Minimum mark.
Add and recheck oil level one quart at a time until the oil level indicator moves into the Safe range
or above the Minimum mark. Do not add additional oil to bring the level to the top of the Safe range
or to the Maximum mark since this may result in overfill and increased oil consumption. If the
accuracy of the engine oil dipstick is in doubt, it may be verified in the following manner:
^ Drain the oil and install a new filter.
^ Put in the specified amount of oil for an oil and filter change. (See owner guide)
^ Start the engine and operate a few minutes.
^ Shut off the engine and allow a few minutes for the oil to drain down.
^ Check the oil level with the dipstick.
^ If the oil level does not indicate in the Safe range or above the Minimum mark, rework or replace
the dipstick.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine oil capacity ...............................................................................................................................
........................................................... 5.0 Qts.(4.7L)
Note: Add 1 Qt. with filter change.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 734
Engine Oil: Fluid Type Specifications
BL Self-adjusting Brake Lubricant
EC Ethylene Glycol Coolant
Mix 50/50 with water to at least -20°F (-29°C) protection
EP Extreme Pressure Gear Lubricant
Ford Part No. D8DZ-19C547-A
FA Automatic Transmission Fluid, Type F
GL-5 Gear Oil, API Service GL-5
HBH Hydraulic Brake Fluid, Extra
Heavy-Duty
HP Hypoid Gear Oil
Ford Part No. E0AZ-19580-A
HP* Hypoid Gear Oil for Limited-Slip
or Traction-Lok Differential
LM Lithium Grease, with Polyethylene
LS Steering Gear Lubricant
MA MERCONAutomatic Transmission
Fluid
MH Manifold Heat Valve Solvent
SG Motor Oil, API Service SG
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Technical Service Bulletins > Oil Filter - Heavy Duty Motorcraft Filter Now Available
Oil Filter: Technical Service Bulletins Oil Filter - Heavy Duty Motorcraft Filter Now Available
Article No. 86-25-17
OIL FILTER - 7.5L ENGINE - HEAVY DUTY MOTORCRAFT FILTER NOW AVAILABLE
LIGHT TRUCK 1974-87 E-250/350, F-250/350
A heavy duty Motorcraft oil filter (FL-1 HP) is now available for use on the 7.5L engine. It is
recommended that vehicles subject to severe service, as outlined in the Owner Guide or off-road
driving, use Motorcraft Oil Filter (FL-1 HP) at all normal oil change intervals.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair
Oil Pan: Service and Repair
Engine oiling system. V8-460
V8-460
1. Remove engine cover, then disconnect battery ground cable and drain cooling system.
2. Remove air cleaner, then disconnect throttle and transmission linkages from carburetor.
3. Disconnect power brake vacuum line, if equipped.
4. Disconnect fuel line and choke lines, then remove air cleaner adapter from carburetor.
5. Disconnect upper and lower radiator hoses and transmission oil cooler lines (if equipped) from
radiator.
6. Remove fan shroud, fan and radiator.
7. On models equipped with power steering, unfasten steering pump and position aside.
8. On all models, remove front engine mount through bolts, then the engine oil dipstick tube.
9. On models equipped with A/C, move refrigerant lines from rear of compressor downward to clear
dash, or remove lines if necessary.
10. On all models, raise and support vehicle.
11. Drain engine oil and remove oil filter.
12. Remove muffler inlet pipe assembly, then disconnect manual and kickdown linkages from
transmission.
13. Remove driveshaft and coupling shaft assembly, then the transmission dipstick tube.
14. Remove dipstick and tube from oil pan, then position a suitable jack and a wooden block under
oil pan. Raise engine slightly until transmission contacts floor, then block engine in place at the
mounts. The engine assembly must be raised exactly four inches and remain centered in the
engine compartment to remove the oil pan.
15. Remove oil pan attaching bolts and lower the pan.
16. Remove oil pump and pickup tube assembly and lay in oil pan, then slide oil pan rearward and
remove from vehicle.
17. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component
Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil
pressure gauge and a sending unit which are connected in series. The sending unit consists of a
diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm
actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil
pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge,
in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor
is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge
reading.
TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions
included with the tester.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning
Lamp/Indicator > Component Information > Testing and Inspection
Oil Pressure Warning Lamp/Indicator: Testing and Inspection
Many trucks utilize a warning light on the instrument panel in place of the conventional dash
indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is
wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil
pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on,
the warning light circuit is energized and the circuit is completed through the closed contacts in the
pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm,
opening the contacts, thereby breaking the circuit and putting out the light.
TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If
it does not light, disconnect the wire from the engine unit and ground the wire to the frame or
cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the
bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the
engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight
and properly grounded, it should be removed and a new one installed. (The presence of sealing
compound on the threads of the engine unit will cause a poor ground). If the warning light remains
lit when it normally should be out, replace the engine unit before proceeding further to determine
the cause for a low pressure indication. The warning light will sometimes light up or flicker when the
engine is idling, even though the oil pressure is adequate. However, the light should go out when
the engine speed is increased.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Technical Service Bulletins > Engine - Oil Pick Up Tube Installation
Oil Pick Up/Strainer: Technical Service Bulletins Engine - Oil Pick Up Tube Installation
Article No. 84-9-18
OIL PICK-UP TUBE (7.5L) - INSTALLATION
LIGHT TRUCKS 1976 TO PRESENT F & E-SERIES
Before installing a new oil pickup tube assembly (E-Series E4UZ-6622-A, F-Series E4TZ-6622-A),
loosen all the oil pump assembly (-6600-) mounting bolts. This action prevents placing
unnecessary stress on the pickup tube due to misalignment during installation. After installing the
new tube assembly, re-torque the oil pump mounting bolts to specification.
PART NUMBER PART NAME CLASS
E4UZ-6622-A Oil Pickup Tube Assembly A
E4TZ-6622-A Oil Pickup Tube Assembly C
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component
Information > Specifications
Oil Pump: Specifications
Rotor Backlash 0.012 in
Note: Maximum inner and outer rotor tip clearance.
Rotor To Body Clearance 0.001-0.013 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 20.6-22.6 lbf at 2.49 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component
Information > Service and Repair > Removal and Installation
Oil Pump: Service and Repair Removal and Installation
V8 ENGINES
On some models, the oil pump must be removed when removing the oil pan. These models are
indicated in the ``Oil Pan, Replace''
procedures.
1. Remove oil pan as previously described.
2. Remove oil pump attaching bolts and the oil pump.
3. To install, prime pump with engine oil and apply sealant to gasket.
4. Insert distributor intermediate shaft, making sure that it is properly seated, then install oil pump.
Do not force pump into place if it will not
readily seat, as the intermediate shaft may be misaligned with distributor shaft. To align, rotate
intermediate shaft until pump can be seated without applying force.
5. Install oil pan.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component
Information > Service and Repair > Removal and Installation > Page 757
Oil Pump: Service and Repair Service
Fig. 42 Oil pump. 6-300
Fig. 43 Oil pump. V8-255, 302, 351W
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component
Information > Service and Repair > Removal and Installation > Page 758
Fig. 44 Oil pump assembly. 351M & 400
ROTOR TYPE PUMP
1. To disassemble, Figs. 42, 43 and 44, remove cover, inner rotor and shaft assembly and outer
race. Remove staking marks at relief valve chamber cap. Insert a self-threading sheet metal screw
of proper diameter into oil pressure relief valve chamber cap and pull cap out of chamber. Then
remove spring and plunger.
2. To assemble, install pressure relief valve plunger, spring and a new cap. Stake cap in place.
Install outer race, inner rotor and shaft. Be sure identification dimple mark on outer race is facing
outward and on the same side as dimple on rotor. Inner rotor and shaft and outer race are
furnished only as a unit. One part should not be replaced without replacing the other.
3. Install pump cover.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
Intake Manifold 22-32 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 762
Intake Manifold: Service and Repair
Fig. 12 Intake manifold tightening sequence. V8-460
Fig. 20 Intake manifold installation. V8 engines
V8-460
1. Drain cooling system, then remove air cleaner and intake duct assembly.
2. Disconnect upper radiator hose from engine and the heater hose from intake manifold and water
pump and position aside.
3. Loosen water pump bypass hose clamp at intake manifold.
4. Disconnect PCV valve hose from right rocker arm cover.
5. Disconnect and tag all vacuum lines at rear of intake manifold.
6. Disconnect ignition wires from spark plugs and position aside.
7. Disconnect high tension lead from ignition coil, then remove distributor cap and wires as an
assembly.
8. Disconnect and tag all distributor vacuum lines at carburetor and vacuum control valve.
9. Disconnect accelerator linkage and transmission kickdown linkage (if equipped).
10. On models equipped with speed control, remove speed control linkage bracket from intake
manifold and disconnect it from carburetor.
11. On all models, remove accelerator linkage cable attaching bolts and position linkage aside.
12. Disconnect fuel inlet line from carburetor.
13. Disconnect electrical connector from ignition coil battery terminal.
14. Disconnect engine temperature and oil pressure sending unit electrical connectors and any
other connectors necessary for intake manifold removal.
15. Unfasten wiring harness from 3 retaining clips on left rocker arm cover and position harness
aside.
16. Remove ignition coil and bracket assembly.
17. Remove intake manifold attaching bolts and nuts, then the intake manifold and carburetor as an
assembly.
18. Reverse procedure to install. Apply sealer as shown in Fig. 20 Torque manifold attaching bolts
to 22-32 ft-lbs as shown in Fig. 12.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge >
Component Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil
pressure gauge and a sending unit which are connected in series. The sending unit consists of a
diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm
actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil
pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge,
in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor
is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge
reading.
TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions
included with the tester.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning
Lamp/Indicator > Component Information > Testing and Inspection
Oil Pressure Warning Lamp/Indicator: Testing and Inspection
Many trucks utilize a warning light on the instrument panel in place of the conventional dash
indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is
wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil
pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on,
the warning light circuit is energized and the circuit is completed through the closed contacts in the
pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm,
opening the contacts, thereby breaking the circuit and putting out the light.
TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If
it does not light, disconnect the wire from the engine unit and ground the wire to the frame or
cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the
bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the
engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight
and properly grounded, it should be removed and a new one installed. (The presence of sealing
compound on the threads of the engine unit will cause a poor ground). If the warning light remains
lit when it normally should be out, replace the engine unit before proceeding further to determine
the cause for a low pressure indication. The warning light will sometimes light up or flicker when the
engine is idling, even though the oil pressure is adequate. However, the light should go out when
the engine speed is increased.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Technical Service Bulletins > Page 775
Crankshaft Main Bearing Seal: Specifications
Main Bearing Cap Bolt Torque
.................................................................................................................................................
129-142 Nm (95-105 ft-lbs)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Removal
Crankshaft Main Bearing Seal: Service and Repair Removal
A split lip-type crankshaft rear oil seal is provided for servicing these engines. 1. Remove the oil
pan and the oil pump, if required. 2. Loosen all the crankshaft main bearing cap bolts, thereby
lowering the crankshaft slightly but not to exceed 0.794 mm (1/32 inch).
CAUTION: Use care to prevent scratching or damaging the crankshaft sealing surfaces.
3. Remove the rear crankshaft main bearing cap, and remove the crankshaft rear oil seal from the
rear crankshaft main bearing cap and cylinder
block. On the cylinder block half of the crankshaft rear oil seal use a seal removal tool, or install a
small metal screw in one end of the crankshaft rear oil seal, and PULL on the screw to remove the
crankshaft rear oil seal.
4. Remove the oil seal retaining pin from the bearing cap if so equipped. The pin is not used with
the split-lip seal.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Removal > Page 778
Crankshaft Main Bearing Seal: Service and Repair Installation
1. Carefully clean the seal groove in the rear crankshaft main bearing cap and cylinder block with a
brush and solvent such as lacquer thinner, Extra
Strength Spot and Stain Remover. Also, clean the area where sealer is later to be applied. Dry the
area thoroughly, so that no solvent touches the crankshaft rear oil seal.
2. Dip the split lip-type seal halves in clean engine oil.
CAUTION: Be sure no rubber has been shaved from the outside diameter of the crankshaft rear oil
seal by the bottom edge of the groove. Do not allow oil to get on the sealer area.
3. Carefully install the upper half of the crankshaft rear oil seal (cylinder block) into its groove with
undercut side of crankshaft rear oil seal toward
the FRONT of the engine, by ROTATING it on the seal journal of the crankshaft until approximately
9.53 mm (3/8 inch) protrudes below the parting surface.
4. Tighten the remaining crankshaft main bearing cap bolts to specifications.
Crankshaft rear oil seal installation
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Removal > Page 779
5. Install the lower half of the crankshaft rear oil seal in the rear crankshaft main bearing cap with
undercut side of crankshaft rear oil seal toward the
FRONT of the engine. Allow the crankshaft rear oil seal to protrude approximately 9.53 mm (3/8
inch) above the parting surface to mate with the upper half of the crankshaft rear oil seal when the
rear crankshaft main bearing cap is installed.
6. Apply a continuous even 1.59 mm (1/16 inch) diameter bead of RTV Silicone Rubber Sealer or
equivalent to the areas shown in the image,
following the procedures given in the illustration.
NOTE: When applying rubber silicone always use the bead size specified and join the components
within 15 minutes of application. After this amount of time the sealant begins to "set-up" and its
sealing effectiveness may be reduced.
7. Install the rear crankshaft main bearing cap. Tighten the bolts to specifications. 8. Install the oil
pump and oil pan. Fill the crankcase with the proper amount and type of oil. 9. Operate the engine
and check for oil leaks.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Technical Service Bulletins > Customer Interest for Front Crankshaft Seal: > 851225 > Jun > 85 >
Engine/Front Crankshaft Seal - Oil Leaks
Front Crankshaft Seal: Customer Interest Engine/Front Crankshaft Seal - Oil Leaks
Article No.85-12-25
LEAKS - OIL, FRONT CRANKSHAFT SEAL (4.9L/7.5L)
LIGHT TRUCK E, F SERIES & BRONCO
A new design front crankshaft oil seal has been released for the 4.9L and 7.5L engines. When
servicing the above concern, replace the current seal (C3AZ- 6700-A) with the new seal
E5TZ-6700-C.
NOTE: This fix is for rear entry seals only.
Figure 14 - ALIGNING CYLINDER FRONT COVER
Refer to the 1985 Shop Manual, Volume B, Section 21-11-17 for removal and installation of the
seal. It is very important to use the front cover aligning tool when reinstalling the front cover. See
Figure 14. PART NUMBER
PART NAME CLASS
E5TZ-6700-C Crankshaft Seal C
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual.
OPERATION/TIME: F Series Econoline
6019A 4.9L 2.6 Hrs. 2.7 Hrs.
6019A 7.5L 2.0 Hrs. 3.0 Hrs.
6019AS1* 4.9L 0.2 Hr. 0.3 Hr.
6019AS1* 7.5L 0.2 Hr. 0.7 Hr.
*Extra time with A/C DLR. CODING: Basic Part No. 6700 - Code: 77
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Crankshaft Seal: > 851225
> Jun > 85 > Engine/Front Crankshaft Seal - Oil Leaks
Front Crankshaft Seal: All Technical Service Bulletins Engine/Front Crankshaft Seal - Oil Leaks
Article No.85-12-25
LEAKS - OIL, FRONT CRANKSHAFT SEAL (4.9L/7.5L)
LIGHT TRUCK E, F SERIES & BRONCO
A new design front crankshaft oil seal has been released for the 4.9L and 7.5L engines. When
servicing the above concern, replace the current seal (C3AZ- 6700-A) with the new seal
E5TZ-6700-C.
NOTE: This fix is for rear entry seals only.
Figure 14 - ALIGNING CYLINDER FRONT COVER
Refer to the 1985 Shop Manual, Volume B, Section 21-11-17 for removal and installation of the
seal. It is very important to use the front cover aligning tool when reinstalling the front cover. See
Figure 14. PART NUMBER
PART NAME CLASS
E5TZ-6700-C Crankshaft Seal C
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual.
OPERATION/TIME: F Series Econoline
6019A 4.9L 2.6 Hrs. 2.7 Hrs.
6019A 7.5L 2.0 Hrs. 3.0 Hrs.
6019AS1* 4.9L 0.2 Hr. 0.3 Hr.
6019AS1* 7.5L 0.2 Hr. 0.7 Hr.
*Extra time with A/C DLR. CODING: Basic Part No. 6700 - Code: 77
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair
Timing Chain: Service and Repair
Fig. 27 Valve timing alignment marks
Fig. 32 Timing marks aligned for correct valve timing. 1982 V6-232
V6-232, V8-255, 302, 351, 400 & 460 After removing the cover as outlined previously, remove the
crankshaft front oil slinger, if equipped. On V6-232 engines, remove camshaft thrust button and
spring from end of camshaft. Crank the engine until the timing marks are aligned as shown in Figs.
31 and 32. Remove camshaft sprocket retaining bolt, washer and fuel pump eccentric. Slide
sprockets and chain forward and remove them as an assembly. Reverse the order of the foregoing
procedure to install the chain and sprockets, being sure the timing marks are properly aligned.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Service and Repair
Timing Cover: Service and Repair
V8-460
1. Drain cooling system and engine oil.
2. Remove radiator shroud and fan, then disconnect radiator hoses from engine.
3. On models equipped with automatic transmission, disconnect oil cooler lines from radiator.
4. On all models, remove radiator upper support and radiator.
5. Loosen alternator mounting bolts and, on models equipped with A/C, the A/C compressor idler
pulley.
6. Remove air pump (if equipped), drive belts and water pump pulley.
7. On models equipped with A/C, remove A/C compressor support from water pump.
8. On all models, remove crankshaft pulley, then the vibration damper and woodruff key.
9. Loosen bypass hose, then disconnect heater return tube from water pump.
10. Disconnect fuel lines from fuel pump, then remove pump. Plug open lines to prevent
contamination.
11. Remove timing case cover attaching bolts, then the timing case cover and water pump as an
assembly.
12. Reverse procedure to install. Apply suitable sealant to cylinder block and timing case cover
gasket surfaces.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications
Fuel Pressure: Specifications
Fuel Pump Pressure (Mechanical) ......................................................................................................
........................................................... 6-8 psi (at idle) Fuel Pump Pressure (Electrical) .....................
.............................................................................................................................................................
4.3 psi
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications > Page 804
Fuel Pressure: Testing and Inspection
1. Connect a suitable pressure gauge (0-15 psi) to the carburetor end of the fuel line (no "T" is
required). 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. The fuel
pump pressure should read 6-8 psi at normal curb idle speed, with the transmission in NEUTRAL,
the engine at normal operating temperatures, and the fuel return line closed (if present). If pump
pressure is too low or too high install a new fuel pump.
3. Reconnect fuel line at filter and install air cleaner.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications
Curb Idle Speed ...................................................................................................................................
................................................ 650 rpm (in DRIVE)
Fast Idle Speed ...................................................................................................................................
........................................... 1600 rpm (in PARK) [1]
[1] On high step of fast idle cam.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure
Air Cleaner Housing: Technical Service Bulletins Air Cleaner - Sealing Procedure
Article No. 83-25-21-S
AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS
WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD
CONDITIONS ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED
LIGHT TRUCKS 1980-83 E, F AND BRONCO
This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the
TSB are of insufficient detail and are therefore being deleted from the TSB.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB.
See your normal parts listing for these part numbers.
The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing
concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles,
a poor running condition. The following procedure should minimize these concerns.
1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the
tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light
trucks except the 1983 Econoline with the 4.9L engine.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB.
See your normal parts listings for these part numbers.
2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that
would prevent a good seal. Replace any damaged components.
3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped
or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the
carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure
a tight bond.
Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A.
FIGURE 24
4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the
radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure
the zip tube to the top of the housing with a nylon tie-down
strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be
reinstalled to the radiator support. 5.
Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in
the air cleaner with an in-line filter.
a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in
the air cleaner, the adapter at the air cleaner and the adapter retaining clip.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 812
b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing
crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does
not need a new hole).
c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs.
2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L).
d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L
and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.).
NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking
into the end of the filter assembly.
e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S.
Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter
(closure) pack hole for 4.9L.
f. Cut the PCV filter (closure) hose to proper length and attach to the adapter.
g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only.
FIGURE 25
6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent
dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25).
a. Remove the carburetor from the vehicle.
b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or
equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the
carburetor. Pay particular attention to the top and bottom of the upper body casting around the
choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air.
c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body
casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper
motor at this time.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 813
FIGURE 24
d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a
toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning
"Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24).
Fill the hole completely around the rods from the top side only and release the throttle lever.
e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off"
position so that choke rod is fully raised. Fast idle cam should remain in "off" position.
f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft
rod. Fill the hole completely around the rod from the bottom side only.
g. Install the spring, pintle, gasket, and stepper motor.
h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV.
i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free)
accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper
body.
j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV
sealant should remain attached to upper body.
k. Re-install carburetor on vehicle.
7. Re-install and secure the air cleaner assembly as follows:
a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray
seating securely and completely sealing the flange.
b. Connect and secure the vacuum hoses.
c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for
4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L.
NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine.
d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing
nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing
to the carburetor is assured.
e. Connect the crankcase filter hose securely.
f. Install the heat riser tube. Connect the fresh air zip tube.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 814
Obtain an Authorized Modifications decal and list the date, dealer number and summary of
alterations performed. Select a prominent place adjacent to the Vehicle Emission Control
Information decal suitable for installing the Authorized Modifications decal. Clean the area, install
the decal and cover it with a clear plastic decal shield. PART NUMBER
PART NAME CLASS
E2AZ-6A768-A PCV Filter C
E2AZ-6853-A 1/2" PCV Hose C
E43Z-9E606-A Adapter C
E2TZ-9601-B Air Filter Element AM
E0TZ-9601-A Air Filter Element AM
C6TZ-9697-A Washer AM
D8ZZ-9654-A Gasket A
377678-S Plug BR
E3AZ-19562-A RTV Sealer A
390013-S36B Wing Nut S
C8DZ-9654-A Gasket AM
OTHER APPLICABLE ARTICLES: 83-25-21 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP9600C84 TIME:
6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start
Fuel Filter: Customer Interest Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 823
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 824
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 825
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85
> Fuel System - Fuel Starvation and Hard Start
Fuel Filter: All Technical Service Bulletins Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85
> Fuel System - Fuel Starvation and Hard Start > Page 831
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85
> Fuel System - Fuel Starvation and Hard Start > Page 832
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85
> Fuel System - Fuel Starvation and Hard Start > Page 833
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 85610 > Mar > 85
> Fuel Filter - Replacement Information
Fuel Filter: All 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filter: > 85610 > Mar > 85 >
Fuel Filter - Replacement Information
Fuel Filter: All 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Ignition Timing Connector > Component Information > Description and Operation
Ignition Timing Connector: Description and Operation
Fig. 20 Ignition Timing Vacuum Switch
Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition
module to retard spark timing. The switch is closed above the vacuum setting and the ignition
module is in the non-retard spark timing mode. Calibration resistors inside the switch control the
amount of retard.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Ignition Timing Connector > Component Information > Description and Operation > Page 850
Ignition Timing Connector: Testing and Inspection
Ignition Timing Vacuum Switch
Ignition Timing Vacuum Switch Test Chart
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less
than'' values in the Ignition Timing vacuum Switch Test chart.
3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured
across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart.
4. Replace switch if resistance is not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Timing Marks and Indicators > System Information > Diagrams
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Testing and Inspection
Ignition Cable: Testing and Inspection
Spark Plug Wire Resistance
*** UPDATED BY TSB #85-9-33
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Advance Unit > Component Information > Specifications
DISTRIBUTOR TIMING ADVANCE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark
Advance Mechanism
Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism
The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly
is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm
assembly used depends on the engine calibration.
Single Diaphragm Assembly
SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the
armature to stator relationship to give spark advance. The stator assembly position is changed by
means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm
assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance
spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached
to the stator assembly, makes the the stator assembly move with respect to the armature. This
changes the initial armature to stator relationship set during initial timing, causing spark advance.
The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly,
is attached to the distributor base.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark
Advance Mechanism > Page 863
Dual Diaphragm Assembly
DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in
the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum
advance port causes the advance diaphragm and attached rod to move, otherwise the action is the
same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard
diaphragm to move, compressing the retard spring, which controls the rate of spark retard.
Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by
the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm
rod moves causing the attached stator assembly to change position with respect to the armature. In
this instance the direction of the stator assembly movement is opposite that occurring during
vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port
overrides any spark retard caused by vacuum being applied to the retard port.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark
Advance Mechanism > Page 864
Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism
Distributor - Exploded view
The centrifugal advance mechanism varies the relationship of the armature to the stator assembly.
The armature is mounted to the sleeve and plate assembly which rotates in relation to the
distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine
RPM. The movement of the weights change the initial relationship of the armature to the stator
assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor
shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by
calibrated springs.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Page 865
Distributor Advance Unit: Service and Repair
1. Remove distributor cap and rotor.
2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup
assembly.
3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link.
4. Carefully remove unit from distributor.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Retard Control > Component Information > Locations
Distributor Retard Control: Locations
Below Vacuum Switch Between No. 5 & No. 6 Spark Plugs
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Vacuum Control > Component Information > Description and Operation
Distributor Vacuum Control: Description and Operation
3-Port Vacuum Regulator
Vacuum Regulator (3 & 4 Port)
Three port, Fig. 27, regulators and four port, Fig. 28, regulators are used to control the vacuum
advance to the distributor. During engine idle conditions, the manifold vacuum signal is reduced to
a constant output signal. Off idle, the output signal equals the spark port.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator
Valve Assembly
Distributor Vacuum Control: Testing and Inspection Distributor Modulator Valve Assembly
1. Turn ignition key to ``ON'' and check resistance at solenoid terminals.
2. If solenoid resistance is not 51---108 ohms, replace solenoid.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator
Valve Assembly > Page 874
Distributor Vacuum Control: Testing and Inspection Vacuum Regulator
Procedure
1. Disconnect vacuum line from distributor port and connect a vacuum gauge.
2. With engine at idle, the vacuum gauge reading should be within 1 inch Hg. vacuum of the
calibration point. The calibration point of each valve can
be identified according to color code as follows: Black, 6 inches Hg.; green, 7 inches Hg.; red, 8
inches Hg.
3. Replace valve if not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair
Distributor Plate W/ Pick-up Sensor: Service and Repair
1. Remove distributor cap and rotor.
2. Remove vacuum advance unit and magnetic pickup assembly.
3. Remove attaching screws and lift base plate from distributor.
4. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Vacuum Spark Delay Valve > Component Information > Description and Operation
Vacuum Spark Delay Valve: Description and Operation
Fig.25 - Spark Delay Valve
This unit is used in conjunction with some of the other Ford systems. Its purpose is to further
reduce emissions by delaying the spark advance during rapid acceleration and by cutting off
advance immediately upon deceleration. Fig. 25.
This plastic disc-shaped valve is installed in the carburetor vacuum line at the distributor advance
diaphragm. It is a one way valve and will not operate if installed backwards. The black side of the
valve must be toward the carburetor. This valve cannot be repaired.
NOTE: On all systems which employ the dual diaphragm distributor the line which has high vacuum
at idle (normal operating temperature) is
connected to the secondary (retard) side of the distributor vacuum advance unit. This is the
connection closest to the distributor cap.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Vacuum Spark Delay Valve > Component Information > Description and Operation > Page 881
Vacuum Spark Delay Valve: Testing and Inspection
Fig.36 - SDV Valve Color Coding
Fig.37 - Spark Delay Valve (SDV) Specifications Chart
Refer to Figs. 36 & 37 for number value by color code.
NOTE: To perform the following procedure, an external vacuum source capable of maintaining a
minimum constant 10 inches Hg. is required.
Mono Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect black side of delay valve to vacuum
source.
2. Connect a vacuum gauge with a 24 inch hose to colored side of delay valve.
3. Apply 10 inches Hg. vacuum and observe time in seconds for gauge to read 0-8 inches Hg. The
minimum and maximum time for gauge to read 8
inches Hg. should be as shown in Fig. 37.
Dual Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect vacuum gauge with a 24 inch hose to
DIST nipple of delay valve.
2. Connect black side of delay valve and CARB nipple of delay valve to vacuum source.
NOTE: Avoid applying vacuum to CARB nipple while applying vacuum to black side of valve.
3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches
Hg. The minimum and maximum time for gauge to
read 8 inches Hg. should be as shown in Fig. 37.
Retard Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect colored side of delay valve to vacuum
source.
2. Connect a vacuum gauge with a 24 inch hose to white side of delay valve.
3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches
Hg. The minimum and maximum time for gauge to
read 8 inches Hg. should be as shown in Fig. 37.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications
Spark Plug: Specifications
Spark Plugs 5-10 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
Compression Pressure Limit Chart
Compression pressures are considered within specification if the lowest reading cylinder is within
25 percent of the highest reading cylinder.
NOTE: Variations exceeding 25 percent indicate an improperly seated valve or worn/broken piston
rings.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 888
Compression Check: Testing and Inspection
1. Warm engine to normal operating temperature, then remove spark plugs and set throttle plates
to wide open position. 2. Install a suitable compression gauge in cylinder No. 1 spark plug hole. 3.
Install an auxiliary starter switch in the starting circuit. 4. With key off, using auxiliary starter switch,
crank engine at least five compression strokes and record highest reading. 5. Repeat test on each
cylinder. 6. Indicated compression pressures are within specification if the lowest reading cylinder
is within 25% of the highest reading.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
Valve Clearance: Specifications
ENGINE YEAR CLEARANCE
V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165
V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150
On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications > Page 892
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications > Page 893
Valve Clearance: Adjustments
Fig. 21 Compressing valve lifter with tool to check clearance on engines with hydraulic valve lifters
V8 ENGINES To provide a means to compensate for dimensional changes in the valve train and
provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve
clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance
is more than the maximum, the longer pushrod should be used. To check the valve clearance,
proceed as follows:
1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of
compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one
quarter turn clockwise (90°) from position No. 2.
2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 1 Intake No. 1 Exhaust No. 7 Intake No. 5 Exhaust No. 8 Intake No. 4
Exhaust V8-351 & 400 No. 1 Intake No. 1 Exhaust No. 4 Intake No. 3 Exhaust No. 8 Intake No. 7
Exhaust
3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 5 Intake No. 2 Exhaust No. 4 Intake No. 6 Exhaust V8-351 & 400 No. 3
Intake No. 2 Exhaust No. 7 Intake No. 6 Exhaust
4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 2 Intake No. 7 Exhaust No. 3 Intake No. 3 Exhaust No. 6 Intake No. 8
Exhaust V8-351 & 400 No. 2 Intake No. 4 Exhaust No. 5 Intake No. 5 Exhaust No. 6 Intake No. 8
Exhaust
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and
Repair
Water Pump: Service and Repair
]All water pumps have a sealed bearing integral with the water pump shaft. The bearing requires no
lubrication. A bleed hole in the pump housing allows water that may leak past the seal to be thrown
out by the slinger. This is not a lubrication hole. If the pump is damaged and requires repair,
replace it with a new pump or a rebuilt one.
V8-460
1. Drain cooling system, then remove fan shroud and fan.
2. On models equipped with power steering, loosen steering pump attaching bolts.
3. On models equipped with A/C, remove A/C compressor upper bracket, then the idler arm and
bracket, compressor drive belt and power steering pump drive belt (if equipped).
4. On models equipped with Thermactor, remove Thermactor pump.
5. On all models, loosen alternator pivot bolt, then remove attaching bolts and spacer.
6. Remove alternator adjustment arm bolt, pivot bolt and drive belt, then the alternator and bracket
as an assembly.
7. On all models equipped with power steering, remove steering pump attaching bolts and position
pump aside.
8. On all models, disconnect lower radiator hose and heater hose from water pump.
9. Remove water pump attaching bolts and the water pump.
10. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Recycled Engine Coolant - Service Tips
Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips
Article No. 95-18-2
09/11/95
^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP
^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP
FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT
1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE
1994 and after ASPIRE 1995 and after CONTOUR
LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN
CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE
1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and
after MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after
BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and
after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after
WINDSTAR
This TSB is being republished in its entirety to include warranty information when using recycled
coolant
ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly
processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda
Coolant Recycler (181-00003) process is the only approved coolant recycling method available
through Ford that is capable of producing recycled engine coolant that meets Ford specification
ESE-M97B44-A.
ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using
Rotunda Coolant Recycler (181-00003).
NOTE:
WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE
PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED
FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY
AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND
LABELING CONCERNS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Recycled Engine Coolant - Service Tips > Page 902
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Recycled Engine Coolant - Service Tips > Page 903
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Coolant Capacity 28 qts
..............................................................................................................................................................
..........................................
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 906
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Temperature Sensor / Switch > Component Information > Specifications
Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Testing and Inspection > Inspection
Fan Blade: Testing and Inspection Inspection
WARNING: Do not operate engine until fan has first been inspected for cracks and/or separations.
If a fan blade is found to be bent or damaged in any way, do not attempt to repair or reuse
damaged part. Proper balance is essential in fan assembly operation. Balance cannot be assured
once a fan assembly has been found to be bent or damaged and failure may occur during
operation, creating an extremely dangerous condition. Always replace damaged fan assembly.
Place fan on flat surface with leading edge facing down. If there is a clearance between fan blade
touching surface and opposite blade of more than .090 inch (2 mm), replace fan.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Testing and Inspection > Inspection > Page 915
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Testing and Inspection > Fan Clutch Fluid Leak
Fan Clutch: Testing and Inspection Fan Clutch Fluid Leak
Small fluid leaks do not generally affect the operation of the unit. These leaks generally occur
around the area of the bearing assembly, but if the leaks appear to be excessive, engine
overheating may occur. Check for clutch and fan free-wheeling by attempting to rotate fan and
clutch assembly by hand five times. If no drag is felt, replace clutch.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 920
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 921
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications
Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component
Information > Locations
Heater Control Valve: Locations
Rear Of Engine Compartment
Above RH Rear Side Of Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips
Heater Core: Technical Service Bulletins Heater Core - Leakage Diagnostic Tips
Article No. 85-8-2
HEATER CORE - LEAK - DIAGNOSTIC TIPS
FORD ALL
LINCOLN-MERCURY ALL
LIGHT TRUCK ALL
Good heater cores are being returned through the parts return system coded as leaking.
Complaints of leaking may be caused by an inadequate seal between the heater hose and the
heater core tubes allowing coolant to follow the tube to the heater core, leak into the passenger
compartment and appear as a leaking heater core.
When diagnosing a suspect heater core leak, inspect the hose to heater core tube attachment to
assure the connection is not leaking. If a leaking connection is found, correct the leak. If the
connection appears not to be leaking, leak test the heater core before removing it from the vehicle
using the following procedure:
HEATER CORE LEAK TEST
Pressure Test 1.
Drain the coolant from the cooling system.
2. Disconnect the heater hoses from the heater core tubes.
3. Install a short piece of heater hose (approximately 4 inches long) on each heater core tube.
Figure 1
4. Fill the heater core and hoses with water and install plug BT-7422-B and adapter BT-7422-A
from Rotunda model 021-00012 or equivalent in the hose ends (Figure 1). Secure the hoses, plug
and adapter with hose clamps.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 933
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 934
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 935
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 936
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test
Temperature Gauge: Testing and Inspection Dash Gauge Test
Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble
should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by
clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the
case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of
the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type
system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable
resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which
maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is
attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip,
causing the pointer to move. As more current passes through the coil, heat increases, moving the
pointer farther. The circuit is completed through a sending unit which contains a variable resistor.
When resistance is high, less current is allowed to pass through the gauge, and the pointer moves
very little. As resistance decreases due to changing conditions in system being monitored, more
current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to
system or ground output terminals of IVR, as damage to system components or wiring circuits may
result.
DASH GAUGE TEST
1. Disconnect battery ground cable and remove gauge from vehicle.
2. Connect ohmmeter between gauge terminals and read coil winding resistance.
3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current
of ohmmeter causes a temperature rise in gauge coil windings.
4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test > Page 942
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection
Temperature Warning Lamp/Indicator: Testing and Inspection
A bimetal temperature switch located in the cylinder head control the operation of a temperature
indicator light with a red lens. If the engine cooling system is not functioning properly and coolant
temperature exceeds a predetermined value, the warning light will illuminate.
TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a
burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when
the engine is running, check the wiring between light and switch for a ground, defective
temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is
functioning properly, a wire which is connected to the ground terminal of the ignition switch is
tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground
terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and
the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled
by the temperature switch.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Specifications
Radiator Cap: Specifications
Release Pressure 13 psi
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Specifications
Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information
> Testing and Inspection > Dash Gauge Test
Temperature Gauge: Testing and Inspection Dash Gauge Test
Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble
should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by
clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the
case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of
the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type
system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable
resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which
maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is
attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip,
causing the pointer to move. As more current passes through the coil, heat increases, moving the
pointer farther. The circuit is completed through a sending unit which contains a variable resistor.
When resistance is high, less current is allowed to pass through the gauge, and the pointer moves
very little. As resistance decreases due to changing conditions in system being monitored, more
current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to
system or ground output terminals of IVR, as damage to system components or wiring circuits may
result.
DASH GAUGE TEST
1. Disconnect battery ground cable and remove gauge from vehicle.
2. Connect ohmmeter between gauge terminals and read coil winding resistance.
3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current
of ohmmeter causes a temperature rise in gauge coil windings.
4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information
> Testing and Inspection > Dash Gauge Test > Page 958
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine
Cooling > Component Information > Testing and Inspection
Temperature Warning Lamp/Indicator: Testing and Inspection
A bimetal temperature switch located in the cylinder head control the operation of a temperature
indicator light with a red lens. If the engine cooling system is not functioning properly and coolant
temperature exceeds a predetermined value, the warning light will illuminate.
TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a
burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when
the engine is running, check the wiring between light and switch for a ground, defective
temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is
functioning properly, a wire which is connected to the ground terminal of the ignition switch is
tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground
terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and
the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled
by the temperature switch.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Service and Repair
Water Pump: Service and Repair
]All water pumps have a sealed bearing integral with the water pump shaft. The bearing requires no
lubrication. A bleed hole in the pump housing allows water that may leak past the seal to be thrown
out by the slinger. This is not a lubrication hole. If the pump is damaged and requires repair,
replace it with a new pump or a rebuilt one.
V8-460
1. Drain cooling system, then remove fan shroud and fan.
2. On models equipped with power steering, loosen steering pump attaching bolts.
3. On models equipped with A/C, remove A/C compressor upper bracket, then the idler arm and
bracket, compressor drive belt and power steering pump drive belt (if equipped).
4. On models equipped with Thermactor, remove Thermactor pump.
5. On all models, loosen alternator pivot bolt, then remove attaching bolts and spacer.
6. Remove alternator adjustment arm bolt, pivot bolt and drive belt, then the alternator and bracket
as an assembly.
7. On all models equipped with power steering, remove steering pump attaching bolts and position
pump aside.
8. On all models, disconnect lower radiator hose and heater hose from water pump.
9. Remove water pump attaching bolts and the water pump.
10. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition
Catalytic Converter: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 974
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 975
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 976
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 977
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 978
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 979
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 980
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition
Catalytic Converter: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 986
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 987
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 988
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 989
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 990
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 991
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 992
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Page 993
Catalytic Converter: Description and Operation
Fig.8 - Catalytic Converter With Single Substrate Catalyst
Fig.9 - Catalytic Converter With Dual Substrate Catalyst
The catalytic converter is an emission control device added to the exhaust system to effectively
reduce the levels of carbon monoxide (CO), hydrocarbons (HC), and in some cases oxides of
nitrogen (NOx), entering the atmosphere. The converter permits a faster chemical reaction to take
place and although it enters into the chemical reaction, it remains unchanged, ready to repeat the
process.
The catalyst in these converters is structured in the form of a honeycomb monolithic composition,
Figs. 8 and 9. The catalyst consists of a porous substrate of an inert material, coated with platinum
and other noble metals (the catalytically active materials).
NOTE: Phase II Catalytic Converters or Dual Catalytic Converters which also control the NOx
emissions, are used on some 1978-82 vehicles.
During engine operation, all of the exhaust gases flow through the converter where a chemical
change takes place. This change causes the temperature inside the converter to be higher than the
temperature of the exhaust gases when they leave the engine. Due to this increase in heat, the
converter is insulated so that its outside temperature is about the same temperature as the muffler.
However, due to its solid mass, the converter remains hot much longer than the muffler.
The body of the catalytic converter is made of stainless steel designed to last the life of the vehicle.
Excessive heat can bulge or distort the converter. Since excessive heat built up is not the fault of
the converter, the carburetion or ignition system should be checked whenever a converter is
damaged by overheating.
Although all vehicles with catalytic converter must use unleaded fuel, small amounts of leaded fuel
can be used in case of an emergency. To prevent adding leaded fuel, the fuel tank filler nozzle has
a built-in restrictor.
Heat shields are used on some vehicles to protect chassis components, passenger compartment,
and other areas from heat damage that may be caused by the catalytic converter.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Page 994
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Page 995
Catalyst and Exhaust Systems
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
Exhaust Manifold 28-32 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications > Page 999
Exhaust Manifold: Service and Repair
V8-460
1. Disconnect battery ground cable.
2. When removing right side exhaust manifold, remove air cleaner, intake duct assembly and heat
shroud.
3. Remove spark plug wires as necessary.
4. Disconnect exhaust pipe at exhaust manifold.
5. Remove attaching bolts and washers, then the exhaust manifold, lifting bracket and spark plug
wire heat shields.
6. Reverse procedure to install, torquing attaching bolts to specifications from centermost bolts
outward.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical
Service Bulletins > Customer Interest: > 84916 > Apr > 84 > Muffler - Wrinkling/Splitting
Muffler: Customer Interest Muffler - Wrinkling/Splitting
Article No. 84-9-16
EXHAUST SYSTEM (7.5L) - MUFFLER REINFORCING CLAMP
LIGHT TRUCKS 1979 THROUGH 1984 ECONOLINE
Some vehicles in severe service such as continuous high-speed ambulance service operations, or
continuous heavy-load operation as in motorhome applications, may experience muffler shell
wrinkling/splitting and leakage at relatively low mileage.
TSB 84-6-22 provided muffler replacement instructions on All E-Series Vehicles Except 10,000
GVW and under with 3.07:1 and 3.54:1 axle ratios in noise-regulated areas.
This article provides muffler reinforcing clamp installation instructions when replacing the muffler on
vehicles excepted above, that is: 10,000 GVW and under with 3.07:1 and 3.54:1 axle ratios in
noise-regulated areas.
FIGURE 16
To service muffler shell wrinkling/splitting and leakage concerns, a muffler reinforcement clamp,
Part No. D9UZ-5A215-A, must be installed on the replacement muffler as shown in Figure 16.
Vehicle application, muffler and reinforcing clamp part numbers are as follows:
Vehicle Application Replacement Mufflers and Muffler
w/7.5L Engines (Only) Reinforcing Clamp Part Numbers
138" W.B. 158" W.B.
Vehicles 10,000 GVW and under E1TZ-5230-G E1TZ-5230-AF
with 3.07:1 and 3.54:1 Axle D9UZ-5A215-A D9UZ-5A215-A
Ratios in Noise-Regulated Areas
PART NUMBER PART NAME CLASS
D9UZ-5A215-A Muffler Clamp C
OTHER APPLICABLE ARTICLES: 84-6-22 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP5215A84 TIME:
0.1 Hr. DLR. CODING: Basic Part No. 5230 Code: 72
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Muffler: > 84916 > Apr > 84 > Muffler - Wrinkling/Splitting
Muffler: All Technical Service Bulletins Muffler - Wrinkling/Splitting
Article No. 84-9-16
EXHAUST SYSTEM (7.5L) - MUFFLER REINFORCING CLAMP
LIGHT TRUCKS 1979 THROUGH 1984 ECONOLINE
Some vehicles in severe service such as continuous high-speed ambulance service operations, or
continuous heavy-load operation as in motorhome applications, may experience muffler shell
wrinkling/splitting and leakage at relatively low mileage.
TSB 84-6-22 provided muffler replacement instructions on All E-Series Vehicles Except 10,000
GVW and under with 3.07:1 and 3.54:1 axle ratios in noise-regulated areas.
This article provides muffler reinforcing clamp installation instructions when replacing the muffler on
vehicles excepted above, that is: 10,000 GVW and under with 3.07:1 and 3.54:1 axle ratios in
noise-regulated areas.
FIGURE 16
To service muffler shell wrinkling/splitting and leakage concerns, a muffler reinforcement clamp,
Part No. D9UZ-5A215-A, must be installed on the replacement muffler as shown in Figure 16.
Vehicle application, muffler and reinforcing clamp part numbers are as follows:
Vehicle Application Replacement Mufflers and Muffler
w/7.5L Engines (Only) Reinforcing Clamp Part Numbers
138" W.B. 158" W.B.
Vehicles 10,000 GVW and under E1TZ-5230-G E1TZ-5230-AF
with 3.07:1 and 3.54:1 Axle D9UZ-5A215-A D9UZ-5A215-A
Ratios in Noise-Regulated Areas
PART NUMBER PART NAME CLASS
D9UZ-5A215-A Muffler Clamp C
OTHER APPLICABLE ARTICLES: 84-6-22 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP5215A84 TIME:
0.1 Hr. DLR. CODING: Basic Part No. 5230 Code: 72
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Muffler: > 84622 > Mar > 84 > Exhaust System - Muffler Replacement
Muffler: All Technical Service Bulletins Exhaust System - Muffler Replacement
Article No. 84-6-22
EXHAUST SYSTEM (7.5L) - MUFFLER REPLACEMENT
LIGHT TRUCKS 1979-84 ECONOLINE
Some vehicles in severe service such as continuous high-speed ambulance service operations, or
continuous heavy-load operation, as in motorhome applications, may experience muffler shell
wrinkling/splitting and leakage at relatively low mileage.
To resolve these concerns, the following mufflers (currently used for 6.9L diesel vehicles) are
specified for service replacement:
Vehicle Application Replacement Muffler
w/7.5L Engine (Only) 138" W.B. 158" W.B.
All E-Series except the following: E3UZ-5230-H E3UZ-5230-J
10,000 GVW and Under with 3.07:1 & 3.54:1 axle ratios in noise-regulated areas.
PART NUMBER PART NAME CLASS
E3UZ-5230-H Muffler C
E3UZ-5230-J Muffler C
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: 5230A TIME:
0.7 Hr. DLR. CODING: Basic Part No. 5230 Code: 72
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Muffler: > 831111 > Jun > 83 > Muffler - Unnecessary Replacement
Muffler: All Technical Service Bulletins Muffler - Unnecessary Replacement
Article No. 83-11-11
EXHAUST - MUFFLER - POWER LOW - UNNECESSARY MUFFLER REPLACEMENT
LIGHT TRUCKS 1982 AND LATER LIGHT TRUCKS
Mufflers are being replaced on leaded fuel vehicles in an effort to resolve concerns of "lack of
power" or poor performance", apparently in the belief that a plugged muffler is the cause. Although
plugging with lead deposits was possible on certain models prior to the 1982 Model Year, muffler
modifications incorporated on 1982 and later models make this an unlikely cause of the concern.
Thus, replacing mufflers on the newer model vehicles normally will not satisfy the customer. Prior
to replacing any muffler believed to be restricted, a vacuum check as described in Section 26-01 of
the Light Truck Shop Manual should be performed.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Muffler: > 84622 > Mar > 84 > Exhaust System - Muffler Replacement
Muffler: All Technical Service Bulletins Exhaust System - Muffler Replacement
Article No. 84-6-22
EXHAUST SYSTEM (7.5L) - MUFFLER REPLACEMENT
LIGHT TRUCKS 1979-84 ECONOLINE
Some vehicles in severe service such as continuous high-speed ambulance service operations, or
continuous heavy-load operation, as in motorhome applications, may experience muffler shell
wrinkling/splitting and leakage at relatively low mileage.
To resolve these concerns, the following mufflers (currently used for 6.9L diesel vehicles) are
specified for service replacement:
Vehicle Application Replacement Muffler
w/7.5L Engine (Only) 138" W.B. 158" W.B.
All E-Series except the following: E3UZ-5230-H E3UZ-5230-J
10,000 GVW and Under with 3.07:1 & 3.54:1 axle ratios in noise-regulated areas.
PART NUMBER PART NAME CLASS
E3UZ-5230-H Muffler C
E3UZ-5230-J Muffler C
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: 5230A TIME:
0.7 Hr. DLR. CODING: Basic Part No. 5230 Code: 72
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Muffler: > 831111 > Jun > 83 > Muffler - Unnecessary Replacement
Muffler: All Technical Service Bulletins Muffler - Unnecessary Replacement
Article No. 83-11-11
EXHAUST - MUFFLER - POWER LOW - UNNECESSARY MUFFLER REPLACEMENT
LIGHT TRUCKS 1982 AND LATER LIGHT TRUCKS
Mufflers are being replaced on leaded fuel vehicles in an effort to resolve concerns of "lack of
power" or poor performance", apparently in the belief that a plugged muffler is the cause. Although
plugging with lead deposits was possible on certain models prior to the 1982 Model Year, muffler
modifications incorporated on 1982 and later models make this an unlikely cause of the concern.
Thus, replacing mufflers on the newer model vehicles normally will not satisfy the customer. Prior
to replacing any muffler believed to be restricted, a vacuum check as described in Section 26-01 of
the Light Truck Shop Manual should be performed.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition
Engine Control Module: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 1041
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 1042
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 1043
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 1044
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 1045
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 1046
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > Customer Interest for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 1047
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition
Engine Control Module: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 1053
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 1054
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 1055
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 1056
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 1057
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 1058
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 1059
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 1060
Engine Control Module: Locations
LH Rear Of Engine Compartment
LH Fender Apron Near Ignition Module
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 1061
Engine Control Module: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
RH Fender Apron w/EEC
Attached To Top Of RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 1065
Main Relay (Computer/Fuel System): Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
RH Fender Apron w/EEC
Attached To Top Of RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 1070
Main Relay (Computer/Fuel System): Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Description and Operation
Ignition Control Module: Description and Operation
Typical Ignition System
The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic
pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short
period of time. High voltage is created each time the magnetic field is built up and collapsed. The
red ignition module wire provides operating voltage for the module's electronic components in the
Run mode. The white module wire and start bypass provide increased voltage for the module and
coil during Start mode.
Ignition Modules
Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control
signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the
Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this
second signal, the UIM provides additional spark timing control for certain operating conditions by
shutting off the ignition coil current flow at a different time than with just the distributor pick-up
signal.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Description and Operation > Page 1075
Module Identification Chart
For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura
Spark II has 6 wire connector while Dura Spark III has a 5 wire connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations
Barometric Pressure Sensor: Locations
In Engine Compartment On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Testing and
Inspection > Barometric Pressure Sensor
Barometric Pressure Sensor: Testing and Inspection Barometric Pressure Sensor
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values
in chart.
3. Replace switch if resistance is not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Testing and
Inspection > Barometric Pressure Sensor > Page 1083
Barometric Pressure Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
RH Front Of Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
1087
Crankshaft Position Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations
EGR Valve Position Sensor: Locations
LH Side Of V8-302/5.
At Center Engine To Rear Of Carburetor
Applicable to: 0L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and
Inspection > Component Testing
Intake Air Temperature Sensor: Testing and Inspection Component Testing
NOTE: Prior to performing any test on this system, insure that temperature switch is above 65° F.
1. Disconnect connector from wiring harness.
2. Connect an ohmmeter or self-powered test light to temperature switch connector terminals.
3. Cool the switch to below 40° F by spraying with Refrigerant 12.
CAUTION: Do not spray refrigerant with engine running, as any refrigerant drawn into the
carburetor and burned in the engine will produce poisonous phosgene gas. Conduct this procedure
in well ventilated area.
4. When switch is cooled below 40° F. a.
On type 1 switches, the internal switch contacts should open. The ohmmeter should read maximum
resistance or the test light should be off. If switch does not open below 40° F, replace switch.
b. On type 2 switches, the internal switch contacts should close. The ohmmeter should read zero
resistance and the test light should be on. If test light does not go on or ohmmeter indicates a
resistance of 1 ohm or more, replace switch.
5. Increase switch temperature to above 70° F by placing palm of hand on metal surface of switch
or by starting engine and allowing the exhaust manifold heat to increase the intake air temperature.
6. When switch temperature is above 70° F. a.
On type 1 switches, the internal switch contacts should close. The ohmmeter should read zero
resistance and the test light should be on. If test light does not go on or ohmmeter indicates a
resistance of 1 ohm or more, replace switch.
b. On type 2 switches, the internal switch contacts should open. The ohmmeter should read
maximum resistance or the test light should be off. If switch does not open, replace switch.
c. If switch is replaced, check operation of new switch before connecting harness connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and
Inspection > Component Testing > Page 1095
Intake Air Temperature Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page
1099
Knock Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
RH Fender Apron w/EEC
In Engine Compartment On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 1103
Manifold Pressure/Vacuum Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
At LH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection >
Speed Sensor Test
Vehicle Speed Sensor: Testing and Inspection Speed Sensor Test
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection >
Speed Sensor Test > Page 1109
Vehicle Speed Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection >
Page 1110
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations
EGR Valve Position Sensor: Locations
LH Side Of V8-302/5.
At Center Engine To Rear Of Carburetor
Applicable to: 0L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations
Fuel Tank Selector Switch: Locations
LH Side Of I/P Near Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel
System - Stalls/No Start/Hesitation/ Stumble
Fuel Pump Inertia Switch: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel
System - Stalls/No Start/Hesitation/ Stumble > Page 1127
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep >
84 > Fuel System - Stalls/No Start/Hesitation/ Stumble
Fuel Pump Inertia Switch: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/
Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep >
84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1133
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
RH Front Of Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1138
Crankshaft Position Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Component Information > Service and Repair
Ignition Switch: Service and Repair
Fig. 3 Ignition switch replacement
1. Disconnect battery ground cable.
2. Remove steering column shroud and lower the steering column.
3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts.
4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Description and Operation
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Page 1145
Knock Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications
Fuel Pressure: Specifications
Fuel Pump Pressure (Mechanical) ......................................................................................................
........................................................... 6-8 psi (at idle) Fuel Pump Pressure (Electrical) .....................
.............................................................................................................................................................
4.3 psi
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Specifications > Page 1150
Fuel Pressure: Testing and Inspection
1. Connect a suitable pressure gauge (0-15 psi) to the carburetor end of the fuel line (no "T" is
required). 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. The fuel
pump pressure should read 6-8 psi at normal curb idle speed, with the transmission in NEUTRAL,
the engine at normal operating temperatures, and the fuel return line closed (if present). If pump
pressure is too low or too high install a new fuel pump.
3. Reconnect fuel line at filter and install air cleaner.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
Curb Idle Speed ...................................................................................................................................
................................................ 650 rpm (in DRIVE)
Fast Idle Speed ...................................................................................................................................
........................................... 1600 rpm (in PARK) [1]
[1] On high step of fast idle cam.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure
Air Cleaner Housing: Technical Service Bulletins Air Cleaner - Sealing Procedure
Article No. 83-25-21-S
AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS
WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD
CONDITIONS ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED
LIGHT TRUCKS 1980-83 E, F AND BRONCO
This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the
TSB are of insufficient detail and are therefore being deleted from the TSB.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB.
See your normal parts listing for these part numbers.
The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing
concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles,
a poor running condition. The following procedure should minimize these concerns.
1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the
tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light
trucks except the 1983 Econoline with the 4.9L engine.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB.
See your normal parts listings for these part numbers.
2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that
would prevent a good seal. Replace any damaged components.
3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped
or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the
carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure
a tight bond.
Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A.
FIGURE 24
4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the
radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure
the zip tube to the top of the housing with a nylon tie-down
strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be
reinstalled to the radiator support. 5.
Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in
the air cleaner with an in-line filter.
a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in
the air cleaner, the adapter at the air cleaner and the adapter retaining clip.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1158
b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing
crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does
not need a new hole).
c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs.
2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L).
d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L
and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.).
NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking
into the end of the filter assembly.
e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S.
Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter
(closure) pack hole for 4.9L.
f. Cut the PCV filter (closure) hose to proper length and attach to the adapter.
g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only.
FIGURE 25
6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent
dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25).
a. Remove the carburetor from the vehicle.
b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or
equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the
carburetor. Pay particular attention to the top and bottom of the upper body casting around the
choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air.
c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body
casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper
motor at this time.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1159
FIGURE 24
d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a
toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning
"Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24).
Fill the hole completely around the rods from the top side only and release the throttle lever.
e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off"
position so that choke rod is fully raised. Fast idle cam should remain in "off" position.
f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft
rod. Fill the hole completely around the rod from the bottom side only.
g. Install the spring, pintle, gasket, and stepper motor.
h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV.
i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free)
accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper
body.
j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV
sealant should remain attached to upper body.
k. Re-install carburetor on vehicle.
7. Re-install and secure the air cleaner assembly as follows:
a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray
seating securely and completely sealing the flange.
b. Connect and secure the vacuum hoses.
c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for
4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L.
NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine.
d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing
nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing
to the carburetor is assured.
e. Connect the crankcase filter hose securely.
f. Install the heat riser tube. Connect the fresh air zip tube.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1160
Obtain an Authorized Modifications decal and list the date, dealer number and summary of
alterations performed. Select a prominent place adjacent to the Vehicle Emission Control
Information decal suitable for installing the Authorized Modifications decal. Clean the area, install
the decal and cover it with a clear plastic decal shield. PART NUMBER
PART NAME CLASS
E2AZ-6A768-A PCV Filter C
E2AZ-6853-A 1/2" PCV Hose C
E43Z-9E606-A Adapter C
E2TZ-9601-B Air Filter Element AM
E0TZ-9601-A Air Filter Element AM
C6TZ-9697-A Washer AM
D8ZZ-9654-A Gasket A
377678-S Plug BR
E3AZ-19562-A RTV Sealer A
390013-S36B Wing Nut S
C8DZ-9654-A Gasket AM
OTHER APPLICABLE ARTICLES: 83-25-21 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP9600C84 TIME:
6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and
Hard Start
Fuel Filter: Customer Interest Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and
Hard Start > Page 1169
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and
Hard Start > Page 1170
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and
Hard Start > Page 1171
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start
Fuel Filter: All Technical Service Bulletins Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 1177
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 1178
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 1179
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 85610 > Mar > 85 > Fuel Filter - Replacement
Information
Fuel Filter: All 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filter: > 831917 > Sep > 83 > Shift Lever
Knob - Pulls Off
Shifter M/T: All Technical Service Bulletins Shift Lever Knob - Pulls Off
Article No. 83-19-17
TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER
LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS
Figure 17
Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is
out of specification. The following procedure is to identify the cause and to service the condition
(See Figure 17).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filter: > 831917 > Sep > 83 > Shift Lever
Knob - Pulls Off > Page 1189
1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert
from the shift ball. Knock the ball off the lever with a block of wood and a hammer.
2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken
or missing pieces are noted. (Retain the plastic shift pattern insert).
3. On T-19 transmission inspect the knurled end of the
shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter
should be between 37/64" and 19/32" in diameter. 4.
If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever
should be replaced with a new one with good knurls. Also install a new shift ball with the new lever.
Figure 17
5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using
the original shift lever and shift ball insert.
NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or
suitable hand grinder, file or grind a radius
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filter: > 831917 > Sep > 83 > Shift Lever
Knob - Pulls Off > Page 1190
or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the
lever and (Figure 17, View A) to aid installation.
6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball
onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the
beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern
insert. NOTE:
Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View
A) below the knurled section of the shift lever assembly.
PART NUMBER PART NAME CLASS
E2TZ-7213-B Shift Ball B
E2TZ-7210-D Shift Lever T-18 R
E3TZ-7210-N Shift Lever T-19 C
E2TZ-7210-C Shift Lever NPG435 B
E2TZ-7210-L Shift Lever SROD R
E2TZ-7210-E Shift Lever M4OD R
E3TZ-7210-A Shift Lever TK 4 spd. C
E4TZ-7210-C Shift Lever TK 5 spd.* C
E2TZ-7210-B Shift Lever NP208/W1345 C
E3TZ-7210-K Shift Lever W-1350 C
* - Shift lever assembly includes shift tower.
OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time
Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210
Code:
01 or 16 as applicable.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filter: > 831917 > Sep > 83 > Shift Lever
Knob - Pulls Off > Page 1196
1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert
from the shift ball. Knock the ball off the lever with a block of wood and a hammer.
2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken
or missing pieces are noted. (Retain the plastic shift pattern insert).
3. On T-19 transmission inspect the knurled end of the
shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter
should be between 37/64" and 19/32" in diameter. 4.
If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever
should be replaced with a new one with good knurls. Also install a new shift ball with the new lever.
Figure 17
5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using
the original shift lever and shift ball insert.
NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or
suitable hand grinder, file or grind a radius
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Filter: > 831917 > Sep > 83 > Shift Lever
Knob - Pulls Off > Page 1197
or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the
lever and (Figure 17, View A) to aid installation.
6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball
onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the
beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern
insert. NOTE:
Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View
A) below the knurled section of the shift lever assembly.
PART NUMBER PART NAME CLASS
E2TZ-7213-B Shift Ball B
E2TZ-7210-D Shift Lever T-18 R
E3TZ-7210-N Shift Lever T-19 C
E2TZ-7210-C Shift Lever NPG435 B
E2TZ-7210-L Shift Lever SROD R
E2TZ-7210-E Shift Lever M4OD R
E3TZ-7210-A Shift Lever TK 4 spd. C
E4TZ-7210-C Shift Lever TK 5 spd.* C
E2TZ-7210-B Shift Lever NP208/W1345 C
E3TZ-7210-K Shift Lever W-1350 C
* - Shift lever assembly includes shift tower.
OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time
Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210
Code:
01 or 16 as applicable.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition
Timing Connector > Component Information > Description and Operation
Ignition Timing Connector: Description and Operation
Fig. 20 Ignition Timing Vacuum Switch
Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition
module to retard spark timing. The switch is closed above the vacuum setting and the ignition
module is in the non-retard spark timing mode. Calibration resistors inside the switch control the
amount of retard.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition
Timing Connector > Component Information > Description and Operation > Page 1205
Ignition Timing Connector: Testing and Inspection
Ignition Timing Vacuum Switch
Ignition Timing Vacuum Switch Test Chart
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less
than'' values in the Ignition Timing vacuum Switch Test chart.
3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured
across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart.
4. Replace switch if resistance is not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing
Marks and Indicators > System Information > Diagrams
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Testing and Inspection
Ignition Cable: Testing and Inspection
Spark Plug Wire Resistance
*** UPDATED BY TSB #85-9-33
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Advance Unit > Component Information > Specifications
DISTRIBUTOR TIMING ADVANCE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism
Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism
The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly
is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm
assembly used depends on the engine calibration.
Single Diaphragm Assembly
SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the
armature to stator relationship to give spark advance. The stator assembly position is changed by
means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm
assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance
spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached
to the stator assembly, makes the the stator assembly move with respect to the armature. This
changes the initial armature to stator relationship set during initial timing, causing spark advance.
The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly,
is attached to the distributor base.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism >
Page 1218
Dual Diaphragm Assembly
DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in
the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum
advance port causes the advance diaphragm and attached rod to move, otherwise the action is the
same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard
diaphragm to move, compressing the retard spring, which controls the rate of spark retard.
Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by
the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm
rod moves causing the attached stator assembly to change position with respect to the armature. In
this instance the direction of the stator assembly movement is opposite that occurring during
vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port
overrides any spark retard caused by vacuum being applied to the retard port.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism >
Page 1219
Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism
Distributor - Exploded view
The centrifugal advance mechanism varies the relationship of the armature to the stator assembly.
The armature is mounted to the sleeve and plate assembly which rotates in relation to the
distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine
RPM. The movement of the weights change the initial relationship of the armature to the stator
assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor
shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by
calibrated springs.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Advance Unit > Component Information > Description and Operation > Page 1220
Distributor Advance Unit: Service and Repair
1. Remove distributor cap and rotor.
2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup
assembly.
3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link.
4. Carefully remove unit from distributor.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Retard Control > Component Information > Locations
Distributor Retard Control: Locations
Below Vacuum Switch Between No. 5 & No. 6 Spark Plugs
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Vacuum Control > Component Information > Description and Operation
Distributor Vacuum Control: Description and Operation
3-Port Vacuum Regulator
Vacuum Regulator (3 & 4 Port)
Three port, Fig. 27, regulators and four port, Fig. 28, regulators are used to control the vacuum
advance to the distributor. During engine idle conditions, the manifold vacuum signal is reduced to
a constant output signal. Off idle, the output signal equals the spark port.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly
Distributor Vacuum Control: Testing and Inspection Distributor Modulator Valve Assembly
1. Turn ignition key to ``ON'' and check resistance at solenoid terminals.
2. If solenoid resistance is not 51---108 ohms, replace solenoid.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly >
Page 1229
Distributor Vacuum Control: Testing and Inspection Vacuum Regulator
Procedure
1. Disconnect vacuum line from distributor port and connect a vacuum gauge.
2. With engine at idle, the vacuum gauge reading should be within 1 inch Hg. vacuum of the
calibration point. The calibration point of each valve can
be identified according to color code as follows: Black, 6 inches Hg.; green, 7 inches Hg.; red, 8
inches Hg.
3. Replace valve if not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair
Distributor Plate W/ Pick-up Sensor: Service and Repair
1. Remove distributor cap and rotor.
2. Remove vacuum advance unit and magnetic pickup assembly.
3. Remove attaching screws and lift base plate from distributor.
4. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Vacuum Spark Delay Valve > Component Information > Description and Operation
Vacuum Spark Delay Valve: Description and Operation
Fig.25 - Spark Delay Valve
This unit is used in conjunction with some of the other Ford systems. Its purpose is to further
reduce emissions by delaying the spark advance during rapid acceleration and by cutting off
advance immediately upon deceleration. Fig. 25.
This plastic disc-shaped valve is installed in the carburetor vacuum line at the distributor advance
diaphragm. It is a one way valve and will not operate if installed backwards. The black side of the
valve must be toward the carburetor. This valve cannot be repaired.
NOTE: On all systems which employ the dual diaphragm distributor the line which has high vacuum
at idle (normal operating temperature) is
connected to the secondary (retard) side of the distributor vacuum advance unit. This is the
connection closest to the distributor cap.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Vacuum Spark Delay Valve > Component Information > Description and Operation > Page 1236
Vacuum Spark Delay Valve: Testing and Inspection
Fig.36 - SDV Valve Color Coding
Fig.37 - Spark Delay Valve (SDV) Specifications Chart
Refer to Figs. 36 & 37 for number value by color code.
NOTE: To perform the following procedure, an external vacuum source capable of maintaining a
minimum constant 10 inches Hg. is required.
Mono Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect black side of delay valve to vacuum
source.
2. Connect a vacuum gauge with a 24 inch hose to colored side of delay valve.
3. Apply 10 inches Hg. vacuum and observe time in seconds for gauge to read 0-8 inches Hg. The
minimum and maximum time for gauge to read 8
inches Hg. should be as shown in Fig. 37.
Dual Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect vacuum gauge with a 24 inch hose to
DIST nipple of delay valve.
2. Connect black side of delay valve and CARB nipple of delay valve to vacuum source.
NOTE: Avoid applying vacuum to CARB nipple while applying vacuum to black side of valve.
3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches
Hg. The minimum and maximum time for gauge to
read 8 inches Hg. should be as shown in Fig. 37.
Retard Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect colored side of delay valve to vacuum
source.
2. Connect a vacuum gauge with a 24 inch hose to white side of delay valve.
3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches
Hg. The minimum and maximum time for gauge to
read 8 inches Hg. should be as shown in Fig. 37.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications
Spark Plug: Specifications
Spark Plugs 5-10 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
Compression Pressure Limit Chart
Compression pressures are considered within specification if the lowest reading cylinder is within
25 percent of the highest reading cylinder.
NOTE: Variations exceeding 25 percent indicate an improperly seated valve or worn/broken piston
rings.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 1243
Compression Check: Testing and Inspection
1. Warm engine to normal operating temperature, then remove spark plugs and set throttle plates
to wide open position. 2. Install a suitable compression gauge in cylinder No. 1 spark plug hole. 3.
Install an auxiliary starter switch in the starting circuit. 4. With key off, using auxiliary starter switch,
crank engine at least five compression strokes and record highest reading. 5. Repeat test on each
cylinder. 6. Indicated compression pressures are within specification if the lowest reading cylinder
is within 25% of the highest reading.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
ENGINE YEAR CLEARANCE
V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165
V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150
On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications > Page 1247
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications > Page 1248
Valve Clearance: Adjustments
Fig. 21 Compressing valve lifter with tool to check clearance on engines with hydraulic valve lifters
V8 ENGINES To provide a means to compensate for dimensional changes in the valve train and
provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve
clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance
is more than the maximum, the longer pushrod should be used. To check the valve clearance,
proceed as follows:
1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of
compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one
quarter turn clockwise (90°) from position No. 2.
2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 1 Intake No. 1 Exhaust No. 7 Intake No. 5 Exhaust No. 8 Intake No. 4
Exhaust V8-351 & 400 No. 1 Intake No. 1 Exhaust No. 4 Intake No. 3 Exhaust No. 8 Intake No. 7
Exhaust
3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 5 Intake No. 2 Exhaust No. 4 Intake No. 6 Exhaust V8-351 & 400 No. 3
Intake No. 2 Exhaust No. 7 Intake No. 6 Exhaust
4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 21, and check the clearance on the following valves:
V8-255, 302, 460 No. 2 Intake No. 7 Exhaust No. 3 Intake No. 3 Exhaust No. 6 Intake No. 8
Exhaust V8-351 & 400 No. 2 Intake No. 4 Exhaust No. 5 Intake No. 5 Exhaust No. 6 Intake No. 8
Exhaust
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A L L Diagnostic Trouble Codes Engine Controls > System Information > System Diagnosis > Transmisson Codes
A L L Diagnostic Trouble Codes - Engine Controls: Testing and Inspection Transmisson Codes
For Transmission related codes, proceed to Computers and Control Systems.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Testing and Inspection > Component Testing
Intake Air Temperature Sensor: Testing and Inspection Component Testing
NOTE: Prior to performing any test on this system, insure that temperature switch is above 65° F.
1. Disconnect connector from wiring harness.
2. Connect an ohmmeter or self-powered test light to temperature switch connector terminals.
3. Cool the switch to below 40° F by spraying with Refrigerant 12.
CAUTION: Do not spray refrigerant with engine running, as any refrigerant drawn into the
carburetor and burned in the engine will produce poisonous phosgene gas. Conduct this procedure
in well ventilated area.
4. When switch is cooled below 40° F. a.
On type 1 switches, the internal switch contacts should open. The ohmmeter should read maximum
resistance or the test light should be off. If switch does not open below 40° F, replace switch.
b. On type 2 switches, the internal switch contacts should close. The ohmmeter should read zero
resistance and the test light should be on. If test light does not go on or ohmmeter indicates a
resistance of 1 ohm or more, replace switch.
5. Increase switch temperature to above 70° F by placing palm of hand on metal surface of switch
or by starting engine and allowing the exhaust manifold heat to increase the intake air temperature.
6. When switch temperature is above 70° F. a.
On type 1 switches, the internal switch contacts should close. The ohmmeter should read zero
resistance and the test light should be on. If test light does not go on or ohmmeter indicates a
resistance of 1 ohm or more, replace switch.
b. On type 2 switches, the internal switch contacts should open. The ohmmeter should read
maximum resistance or the test light should be off. If switch does not open, replace switch.
c. If switch is replaced, check operation of new switch before connecting harness connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Testing and Inspection > Component Testing > Page 1258
Intake Air Temperature Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition
Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1267
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1268
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1269
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1270
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1271
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1272
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1273
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Lack of Power and/or No
Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1279
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1280
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1281
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1282
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1283
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1284
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1285
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor >
Component Information > Locations
Barometric Pressure Sensor: Locations
In Engine Compartment On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor >
Component Information > Testing and Inspection > Barometric Pressure Sensor
Barometric Pressure Sensor: Testing and Inspection Barometric Pressure Sensor
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values
in chart.
3. Replace switch if resistance is not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor >
Component Information > Testing and Inspection > Barometric Pressure Sensor > Page 1291
Barometric Pressure Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations
Crankshaft Position Sensor: Locations
RH Front Of Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Locations > Page 1295
Crankshaft Position Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer >
Component Information > Description and Operation
EGR Backpressure Transducer: Description and Operation
Fig.49 - Integral EGR Valve Exhaust Back-pressure Transducer
This valve, Fig. 49, performs the same function as the non-integral back pressure transducer used
on some systems. The valve assembly has an internal exhaust gas chamber with a transducer
diaphragm which senses exhaust back pressure through a hollow stem. When back pressure is
low, vacuum is bled through the transducer valve and the EGR valve stem remains closed. When
back pressure increases, the transducer diaphragm moves up and closes the transducer valve
vacuum bleed hole.
With the vacuum bleed closed, the EGR valve opens, allowing exhaust gas to flow into the intake
manifold. Because the EGR outlet is always exposed to manifold vacuum and EGR gas inlet flow is
restricted by an orifice, back pressure at the transducer drops when the EGR valve opens. When
the back pressure drops, the vacuum bleed hole opens, closing the EGR valve and allowing
pressure to build up again. The cycle is continually repeated, modulating the flow of exhaust gas
into the intake manifold.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Locations
EGR Valve Position Sensor: Locations
LH Side Of V8-302/5.
At Center Engine To Rear Of Carburetor
Applicable to: 0L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition
Engine Control Module: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1310
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1311
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1312
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1313
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1314
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1315
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest for Engine Control Module: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1316
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition
Engine Control Module: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1322
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1323
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1324
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1325
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1326
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1327
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1328
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 1329
Engine Control Module: Locations
LH Rear Of Engine Compartment
LH Fender Apron Near Ignition Module
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 1330
Engine Control Module: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid >
Component Information > Locations
Feedback Control Solenoid: Locations
Top Of V8-460/7.
LH Front Of Carburetor
Applicable to: 5 Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid >
Component Information > Locations > Page 1334
Feedback Control Solenoid: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve
Idle Speed Vacuum Solenoid Valve: Locations Throttle Kicker Vacuum Valve
RH Side Of V8-460/7.
Top Of 8 Cyl. Engine, LH Side of 6 Cyl. Engine
Applicable to: 5L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve >
Page 1340
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Description and Operation
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Description and Operation > Page 1344
Knock Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
RH Fender Apron w/EEC
Attached To Top Of RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 1348
Main Relay (Computer/Fuel System): Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
RH Fender Apron w/EEC
In Engine Compartment On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations > Page 1352
Manifold Pressure/Vacuum Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Engine Control Module: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1362
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1363
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1364
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1365
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1366
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1367
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1368
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Engine Control Module: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1374
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1375
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1376
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1377
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1378
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1379
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1380
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Engine Control Module: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble
Fuel Pump Inertia Switch: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/
Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Engine Control Module: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page
1386
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Engine Control Module: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page
1392
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 1393
Engine Control Module: Locations
LH Rear Of Engine Compartment
LH Fender Apron Near Ignition Module
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 1394
Engine Control Module: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
RH Fender Apron w/EEC
Attached To Top Of RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1398
Main Relay (Computer/Fuel System): Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Locations
Barometric Pressure Sensor: Locations
In Engine Compartment On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Testing and Inspection >
Barometric Pressure Sensor
Barometric Pressure Sensor: Testing and Inspection Barometric Pressure Sensor
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values
in chart.
3. Replace switch if resistance is not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Testing and Inspection >
Barometric Pressure Sensor > Page 1405
Barometric Pressure Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
RH Front Of Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1409
Crankshaft Position Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations
EGR Valve Position Sensor: Locations
LH Side Of V8-302/5.
At Center Engine To Rear Of Carburetor
Applicable to: 0L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection >
Component Testing
Intake Air Temperature Sensor: Testing and Inspection Component Testing
NOTE: Prior to performing any test on this system, insure that temperature switch is above 65° F.
1. Disconnect connector from wiring harness.
2. Connect an ohmmeter or self-powered test light to temperature switch connector terminals.
3. Cool the switch to below 40° F by spraying with Refrigerant 12.
CAUTION: Do not spray refrigerant with engine running, as any refrigerant drawn into the
carburetor and burned in the engine will produce poisonous phosgene gas. Conduct this procedure
in well ventilated area.
4. When switch is cooled below 40° F. a.
On type 1 switches, the internal switch contacts should open. The ohmmeter should read maximum
resistance or the test light should be off. If switch does not open below 40° F, replace switch.
b. On type 2 switches, the internal switch contacts should close. The ohmmeter should read zero
resistance and the test light should be on. If test light does not go on or ohmmeter indicates a
resistance of 1 ohm or more, replace switch.
5. Increase switch temperature to above 70° F by placing palm of hand on metal surface of switch
or by starting engine and allowing the exhaust manifold heat to increase the intake air temperature.
6. When switch temperature is above 70° F. a.
On type 1 switches, the internal switch contacts should close. The ohmmeter should read zero
resistance and the test light should be on. If test light does not go on or ohmmeter indicates a
resistance of 1 ohm or more, replace switch.
b. On type 2 switches, the internal switch contacts should open. The ohmmeter should read
maximum resistance or the test light should be off. If switch does not open, replace switch.
c. If switch is replaced, check operation of new switch before connecting harness connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection >
Component Testing > Page 1417
Intake Air Temperature Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Page 1421
Knock Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
RH Fender Apron w/EEC
In Engine Compartment On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1425
Manifold Pressure/Vacuum Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
At LH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed
Sensor Test
Vehicle Speed Sensor: Testing and Inspection Speed Sensor Test
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed
Sensor Test > Page 1431
Vehicle Speed Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 1432
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations
Vehicle Speed Sensor: Locations
At LH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Testing and Inspection > Speed Sensor Test
Vehicle Speed Sensor: Testing and Inspection Speed Sensor Test
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Testing and Inspection > Speed Sensor Test > Page 1438
Vehicle Speed Sensor: Testing and Inspection Computer Related Diagnostic Information
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Testing and Inspection > Page 1439
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid >
Component Information > Locations > Thermactor Air Bypass (TAB) Solenoid
Air Diverter Solenoid: Locations Thermactor Air Bypass (TAB) Solenoid
At RH Of Vacuum Switch On Valve Cover
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid >
Component Information > Locations > Thermactor Air Bypass (TAB) Solenoid > Page 1446
Air Diverter Solenoid: Locations Thermactor Air Diverter (TAD) Solenoid
Top Of V8-460/7.
At RH Of Vacuum Switch On Valve Cover
Applicable to: 5 Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation
Air Diverter Valve: Description and Operation
Fig.71 - Air Pump Mounted Timed Air Bypass Valve
Fig.72 - Timed Air Bypass Valve
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation > Page 1450
Fig.73 - Normally Closed Timed Air Bypass Valve
Fig.74 - Timed Air Bypass Valve With Integral Function
DESCRIPTION
Some 1966-67 vehicles use a bypass type anti-backfire valve in place of the "gulp" type system.
The valve operates at all times and all output air from the air pump is routed through it. The air flow
to the manifolds is temporarily interrupted and diverted to the air pump air cleaner during
deceleration.
The air bypass system on 1968-82 vehicles serves the same purpose as earlier types, but three
different types of bypass valves are used, depending on application. These are: a timed bypass
valve, a normally closed bypass valve, or a timed bypass valve with an integral vacuum function.
They are mounted "in-line," or on the air pump. Figs. 71, 72, 73, and 74.
On systems using a timed bypass valve, Figs. 71 and 72, during normal operation, vacuum is
equalized on both sides of the diaphragm. The diaphragm return spring holds the valve closed, and
allows air to flow to the exhaust ports. During deceleration, the sudden rise of intake manifold
vacuum under the diaphragm overcomes return spring pressure and pulls the valve down. The air
flow is then momentarily diverted to atmosphere, because vacuum is quickly equalized again on
both sides of the diaphragm through a small orifice in the diaphragm.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation > Page 1451
The normally closed timed bypass valve, Fig. 73, is used on vehicles with catalytic converter.
During normal operation, engine manifold vacuum applied through the vacuum differential valve
(VDV) holds the valve upward, allowing thermactor air to flow to the exhaust manifolds and
blocking the vent port. When intake manifold vacuum rises or drops sharply, the VDV operates and
momentarily cuts off the vacuum to the bypass valve.
The spring pulls the stem down, seating the valve to cut off pump air to the exhaust manifolds and
dumping the dump valve to momentarily divert the air to atmosphere. If air pump pressure
becomes excessive or there is a restriction in the system, the excess pressure will unseat the valve
in the lower portion of the bypass valve and allow a partial flow of pump air to the atmosphere,
while at the same time, the valve in the upper part of the bypass is still unseated, allowing a partial
flow of pump air to the exhaust manifold to meet system requirements.
The timed air bypass valve with an integral vacuum differential function, Fig. 74, is used on some
thermactor systems. This valve contains an integral vacuum differential function, therefore a
separate vacuum differential valve (VLV) is not required. When the vent is blocked, the valve
functions as a timed bypass valve with a VDV. However, when the vent is open to atmospheric
pressure, and a vacuum of 4 inches Hg or more is applied to the source port, the valve goes to the
dump mode.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Testing and Inspection > Normally Closed (Type 1) Solenoid Vacuum Valve
Air Diverter Valve: Testing and Inspection Normally Closed (Type 1) Solenoid Vacuum Valve
Note:
A type 1 solenoid vacuum valve is used in conjunction with a type 1 air cleaner temperature switch.
Procedure:
1. Start engine and allow to reach normal operating temperature. Make sure that ambient air
around air cleaner is above 65° F.
2. With engine idling, disconnect vacuum hose to thermactor air bypass valve. Thermactor air
should exhaust in atmosphere through exhaust ports in
end of valve silencer cover. Reconnect vacuum hose.
NOTE: Vacuum supply hose must always be connected to bottom vacuum fitting on solenoid
vacuum valve.
3. Disconnect vacuum supply hose at solenoid valve, and check for vacuum by placing finger over
end of hose. There should be vacuum with engine
idling. If not, check vacuum hose and vacuum source for leaks or obstructions.
4. Disconnect solenoid vacuum valve wiring connector and determine which terminal has 12 volts
with ignition in the run position. Use a test light;
connect one end to terminal and other end to ground.
5. Connect wire with 12 volts battery voltage to solenoid vacuum valve. With engine idling, ground
other exposed terminal on solenoid vacuum
valve to chassis ground. Thermactor air should not be dumped.
6. Reconnect wire disconnected in step 4 to solenoid vacuum valve. Thermactor air should not be
dumped.
7. Replace solenoid vacuum valve if operation is not as specified in steps 5 and 6.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Testing and Inspection > Normally Closed (Type 1) Solenoid Vacuum Valve > Page 1454
Air Diverter Valve: Testing and Inspection Normally Open (Type 2) Solenoid Vacuum Valve
Note:
A type 2 solenoid vacuum valve is used in conjunction with a type 2 air cleaner temperature switch.
Procedure
1. Start engine and allow to reach normal operating temperature. Make sure that ambient air
around air cleaner is above 65° F.
2. With engine idling, disconnect vacuum hose to thermactor air bypass valve. Thermactor air
should exhaust to atmosphere through exhaust ports in
end of valve silencer cover. Reconnect vacuum hose.
NOTE: Vacuum hose must be connected to black input nozzle on solenoid valve.
3. Disconnect wiring to solenoid valve and determine which wire has 12 volts when ignition switch
is in the run position. Use a test light; connect one
end to wire and other end to ground.
4. Connect wire power supply wire to solenoid vacuum valve, then with engine at normal idle,
ground other exposed terminal on solenoid vacuum
valve to ground. Thermactor air should be exhausted to atmosphere.
5. Reconnect other wire to solenoid vacuum valve. Thermactor air should not be dumped to
atmosphere.
6. Replace solenoid vacuum valve if operation is not as specified in steps 4 and 5.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve
> Component Information > Description and Operation
Air Injection Bypass Valve: Description and Operation
Normally closed timed air bypass valve.
Normally open timed air bypass valve with vacuum vent.
Normally open timed air bypass valve less vacuum vent.
The air bypass system serves the same purpose as earlier types, but three different types of
bypass valves are used, depending on application. These are: normally closed bypass valve,
normally open bypass valve with vacuum vent and normally open bypass valve without vacuum
vent. They are mounted "inline", or on the air pump, Figs. 85, 86 and 87.
The normally closed timed bypass valve, Fig. 85, is used on vehicles with catalytic converter.
During normal operation, engine manifold vacuum applied through the vacuum differential valve
(VDV) holds the valve upward, allowing thermactor air to flow to the exhaust manifolds and
blocking the vent port. When intake manifold vacuum rises or drops sharply, the VDV operates and
momentarily cuts off the vacuum to the bypass valve. The spring
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve
> Component Information > Description and Operation > Page 1458
pulls the stem down, seating the valve to cut off pump air to the exhaust manifolds and dumping
the dump valve to momentarily divert the air to atmosphere. If air pump pressure becomes
excessive or there is a restriction in the system, the excess pressure will unseat the valve in the
lower portion of the bypass valve and allow a partial flow of pump air the atmosphere, while at the
same time, the valve in the upper part of the bypass is still unseated, allowing a partial flow of
pump air to the exhaust manifold to meet system requirements. The normally open timed bypass
valve with vacuum vents, Fig. 86, provides a timed air dump during deceleration and when
differences in vacuum pressure between the signal port and vent port occur. The signal port must
have 3 inches Hg more vacuum than the vent port to prevent the valve from dumping. The valve is
used to protect catalyst overheating. The normally open timed bypass valve without vacuum vents
supplies air to the exhaust system with a higher than normal vacuum signal during cold start, short
idles is applied, pump air is dumped through the silencer ports of the valve, Fig. 87.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve
> Component Information > Description and Operation > Page 1459
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve
> Component Information > Description and Operation
Air Injection Check Valve: Description and Operation
This valve, used on some vehicles, allows thermactor air to enter exhaust port drillings, but
prevents reverse flow of exhaust gases in event of improper operation of system components. This
valve is located between bypass valve and exhaust port drillings, either on air manifold or engine.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve
> Component Information > Description and Operation > Page 1463
Air Injection Check Valve: Testing and Inspection
1. Check valves should be inspected whenever the hose is disconnected from the valve or check
valve failure is suspected.
NOTE: Any indication of exhaust gases in the air pump indicates check valve failure.
2. Orally blow through the check valve (toward air manifold) then attempt to suck back. Flow should
be toward air manifold only.
3. When replacing a check valve, be careful not to bend or twist the air manifold.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve
> Component Information > Description and Operation > Page 1464
Air Injection Check Valve: Service and Repair
PROCEDURE
1. Disconnect air supply valve from hose and, using a 1 1/4 inch crow-foot wrench, remove check
valve.
2. Clean threads on air manifold adapter using a wire brush, then install new check valve.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Description and Operation > Air Supply Control Valves
Air Injection Control Valve: Description and Operation Air Supply Control Valves
Fig.75 - Standard Air Control Valve
Fig.76 - Air Control & Shut Off Valve
Fig.77 - Air Control & Shut Off Valve With Orifice
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Description and Operation > Air Supply Control Valves > Page 1469
DESCRIPTION
These valves are used to direct air pump output to the exhaust manifold or downstream to the
catalyst system depending on the engine control modes.
Three types of valves are used, the standard air control valve, Fig. 75, the air control/shut off valve
with orifice, Fig. 76, and the air control/shut off valve, Fig. 77.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Description and Operation > Air Supply Control Valves > Page 1470
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Description and Operation > Air Supply Control Valves > Page 1471
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Description and Operation > Air Supply Control Valves > Page 1472
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Testing and Inspection > Air Control Valve
Air Injection Control Valve: Testing and Inspection Air Control Valve
Fig. 67 Standard air control valve. 1983---87
Standard Air Control Valve
1. Run engine at 1500 RPM and disconnect air supply hose at inlet, Fig. 67. There should be air
flow at hose. Reconnect air supply hose at valve inlet.
2. Disconnect air supply hoses at outlets A and B and the vacuum line at the vacuum nipple.
3. Run engine at 1500 RPM. There should be air flow at outlet B but little or no air flow at outlet A.
4. Run engine at 1500 RPM and connect a direct vacuum line from any manifold vacuum fitting to
air control valve vacuum nipple. There should be air flow at outlet A but little or no air flow at outlet
B.
5. Connect all vacuum hoses at original positions. If valve does not function correctly, replace
valve.
AIR CONTROL/SHUT-OFF VALVE
1. Start engine and run at idle, disconnect vacuum supply hose from vacuum nipple, and
disconnect inlet hose from valve. Suction should be felt at valve opening.
2. Apply manifold vacuum to vacuum nipple. No suction should be felt at valve inlet opening.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Testing and Inspection > Air Control Valve > Page 1475
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Testing and Inspection > Air Control Valve > Page 1476
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Testing and Inspection > Air Control Valve > Page 1477
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Testing and Inspection > Air Control Valve > Page 1478
Air Injection Control Valve: Testing and Inspection Thermactor Vacuum Vent Valve
1. If necessary, remove air cleaner assembly.
2. Disconnect vacuum tubing or connector block from valve, noting location of tubing. It may be
necessary to remove valve from bracket or air cleaner tray to gain access to vacuum ports on
valve.
3. Connect the black vacuum port to a manifold vacuum source.
4. Connect an external vacuum source to white body vacuum port.
5. With engine idling in neutral, apply 10 inches Hg vacuum to white port and trap. If vacuum
cannot be obtained, replace valve.
6. Remove manifold vacuum source line from black port. The trapped vacuum should drop to zero.
If not, replace valve.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Testing and Inspection > Air Control Valve > Page 1479
Air Injection Control Valve: Testing and Inspection Vacuum Differential Valve (VDV)
1. Start engine and allow to reach normal operating temperature with transmission in Park or
Neutral and parking brake applied.
2. Stop engine and remove air bypass valve to air manifold check valve hose and bypass valve. On
systems with two check valves, remove both hoses. Connect tachometer to engine.
3. Start engine, then with hand placed over bypass valve outlet connections, accelerate engine to
2500 RPM and release throttle, allowing engine to return to normal idle. During deceleration, the air
flow in the valve outlet should be felt or heard to momentarily diminish or stop and then resume to
normal air flow. Air flow will be discharged through the exhaust ports in the end of the bypass valve
silencer cover.
4. If bypass valve does not function as described in step 3, check to make sure that decel valve is
receiving a vacuum signal. If it is, the decel valve is defective and should be replaced.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Filter >
Component Information > Service and Repair
Air Injection Filter: Service and Repair
Fig. 68 Removing centrifugal type air pump filter
Centrifugal Filter Fan, Replace
1. Remove drive pulley and outer disc from air pump.
2. Remove filter fan from pump, Fig. 90.
NOTE: Do not attempt to remove the metal drive hub.
3. Install new filter fan using the pulley and bolts. Alternately tighten bolts to draw fan down evenly.
NOTE: A slight interference between the fan and housing is normal. A new fan may make noise
during initial operation, until it's outer diameter sealing lip has worn in, after approximately 20-30
miles of operation.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Hose/Tube >
Component Information > Testing and Inspection
Air Injection Hose/Tube: Testing and Inspection
CAUTION:
The hoses used with this system are made of special material to withstand high temperature. No
other type should be used.
Procedure:
1. Inspect all hoses and tubes for deterioration or cracks.
2. Check hose and tube routing as interference may cause wear.
3. Check all hose and tube connections.
4. Check the pressure side of the system for leaks with a soapy water solution. With the pump
running, bubbles will form if a leak exists.
5. When replacing any hose or tube, note routing before removal.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Manifold Rails <--> [Air
Injection Manifold] > Component Information > Testing and Inspection
Air Manifold Rails: Testing and Inspection
CAUTION:
The hoses used with this system are made of special material to withstand high temperature. No
other type should be used.
Procedure:
1. Inspect all hoses and tubes for deterioration or cracks.
2. Check hose and tube routing as interference may cause wear.
3. Check all hose and tube connections.
4. Check the pressure side of the system for leaks with a soapy water solution. With the pump
running, bubbles will form if a leak exists.
5. When replacing any hose or tube, note routing before removal.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Manifold Rails <--> [Air
Injection Manifold] > Component Information > Testing and Inspection > Page 1489
Air Manifold Rails: Service and Repair
PROCEDURE
1. Disconnect air supply hose from check valve and position hose aside.
2. Unscrew air manifold to cylinder head coupling nuts until free of the cylinder head, then remove
air manifold.
3. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air
Injection Pump] > Component Information > Technical Service Bulletins > Exhaust Air Pump Assembly - Obsolete Part
Return
Air Pump: Technical Service Bulletins Exhaust Air Pump Assembly - Obsolete Part Return
Article No. 93-3-11
February 3, 1993
SERVICE PARTS RETURN OF OBSOLETE EXHAUST AIR PUMP ASSEMBLY
FORD: 1981 FAIRMONT, THUNDERBIRD
LINCOLN-MERCURY: 1981 COUGAR, MONARCH
LIGHT TRUCK: 1981-83 ECONOLINE 1981-86 F-150-350 SERIES 1986 BRONCO
ISSUE: Exhaust Air Pump Assembly (E1TZ-9A486-D) (CX-631) may not meet Ford's high quality
requirements and should be withdrawn from your inventory. This Sort and Purge of part numbers
(E1TZ-9A486-D) (CX-631) which lack the threaded mounting hole should be withdrawn from your
inventory and returned to your facing PDC within 30 days of this TSB.
ACTION: Return the obsolete parts from your dealership's inventory.
1. Sort stock (E1TZ-9A486-D) (CX-631) which lacks the threaded mounting hole.
2. Return part numbers (E1TZ-9A486-D) (CX-631) which lack this threaded hole and return to your
facing PDC using the least expensive transportation.
3. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a
separate FPS-340 claim for these parts.
4. Indicate Reason "J" on claims.
5. In the Remarks Section write "Returned per TSB 93-3-11".
LIMITS
^ The returns must be received within 30 days from the date of this TSB.
^ Returns are restricted to the subject parts.
^ The parts returned must have been purchased from FPSD in accordance with Policy and
Procedure Bulletin 4000.
CREDIT
Credit for parts and prepaid freight costs will be issued.
NOTE: REPLACEMENT STOCK IS AVAILABLE FOR ORDERING IMMEDIATELY.
PART NUMBER PART NAME CLASS
E1TZ-9A486-D Exhaust Air Pump Assembly AM
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 403000, 623000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air
Injection Pump] > Component Information > Technical Service Bulletins > Page 1494
Air Pump: Testing and Inspection
PROCEDURE
1. Remove air cleaner, then inspect all hoses and hose connections for leaks. Correct as
necessary. Check belt tension and correct as necessary.
2. With transmission in Park or Neutral with parking brake applied, start engine and allow it to reach
normal operating temperature.
3. Stop engine. Disconnect air supply hose(s) from air pump to air bypass valve from pump.
4. Install Rotunda T57L-9486-A or equivalent thermactor test gauge in end of hose disconnected
from bypass valve. Secure hose with clamp to
prevent it from blowing out. On side or cover mounted bypass valves, install an elbow and hose
adapter, then install test gauge.
CAUTION: Position air pump supply tester so that air blast emitted will be harmlessly dissipated.
5. Connect tachometer to engine and start engine. Slowly increase engine speed to 1000 rpm while
observing pressure at gauge. Air pump pressure
should be at least 2 1/4 psi. If rotunda tool is not used, increase engine speed to 1500 rpm and
place hand over open hose. Air flow should be heard and felt.
6. If air pump output pressure is not at least 2 1/4 psi, or if air flow is not heard and felt, replace
pump and repeat test.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air
Injection Pump] > Component Information > Service and Repair > Air Injection Pump, Replace
Air Pump: Service and Repair Air Injection Pump, Replace
1. Disconnect air inlet and outlet hoses from air pump.
2. Remove drive belt and mounting bolts from pump and remove the pump.
3. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air
Injection Pump] > Component Information > Service and Repair > Air Injection Pump, Replace > Page 1497
Air Pump: Service and Repair Air Pump Relief Valve, Replace
NOTE:
The air pump does not have to be disassembled to replace the relief valve; however, it must be
removed from the engine.
PROCEDURE
1. Install Tool T66L-9A486-D on air pump and remove relief valve using a suitable slide hammer.
2. To install relief valve, use Tool T66L- 9A4S6-B and lightly hammer the valve until it is seated.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air
Injection Pump] > Component Information > Service and Repair > Air Injection Pump, Replace > Page 1498
Air Pump: Service and Repair Relief Valve Pressure Setting Plug, Replace
PROCEDURE
1. Compress shoulders of pressure setting plug together and pull plug out of relief valve.
2. Install new valve into relief valve hole by pressing against its center with a suitable tool.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Pulsed Secondary Air
Injection > Component Information > Description and Operation
Pulsed Secondary Air Injection: Description and Operation
Fig. 79 Thermactor II system (typical)
Fig. 80 Thermactor II pulse air valve operation
Some engines are equipped with this type of exhaust air injection system, Fig. 79, which does not
have an air pump. The system uses the natural pulses of the exhaust system to draw air into the
exhaust manifold. The system is regulated by a pulse air valve. The valve, Fig. 80, is connected to
the air cleaner with a hose and to the exhaust manifold with a metal tube. Some pulse air valves
closely resemble the standard Thermactor check valves, but are not interchangeable with them.
When pressure inside the exhaust manifold is more than the pressure in the air cleaner, the reed in
the pulse air valve is closed. When pressure in the exhaust manifold is lower than in the air
cleaner, the reed opens and allows air to be drawn into the exhaust manifold.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve,
Air Injection > Component Information > Description and Operation
Thermal Vacuum Valve: Description and Operation
Fig. 27 Temperature vacuum switch--TVS
This switch, Fig. 27, used on some vehicles, has a bimetal disc which locates itself in one of two
positions, depending on its temperature. One position allows free air flow in the vacuum line; and
the other blocks air flow by sealing itself against the O-ring. The switching temperature is below the
range of normal engine operating temperature.
The TVS may be used to control the vacuum signal to the thermactor dump valve, to reduce
emissions.
The normally open TVS may block the purge vacuum signal to provide satisfactory cold driveability
and reduce cold engine emissions. It may be also used to hold off EGR operation during cold
engine operation.
The normally closed TVS may allow cold spark advance to provide satisfactory cold engine
driveability.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve,
Air Injection > Component Information > Testing and Inspection > Electric PVS High Temp Coolant Lock Out Vacuum
Thermal Vacuum Valve: Testing and Inspection Electric PVS High Temp Coolant Lock Out
Vacuum
1975-82 Vehicles With Catalytic Converter
1. Disconnect vacuum line from air bypass valve to PVS valve at air bypass valve and connect to
vacuum gauge.
2. With transmission in Park or Neutral and parking brake applied, start engine and allow to idle.
3. With engine at normal operating temperature, there should be a vacuum reading. If not, PVS is
defective and should be replaced.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve,
Air Injection > Component Information > Testing and Inspection > Electric PVS High Temp Coolant Lock Out Vacuum >
Page 1507
Thermal Vacuum Valve: Testing and Inspection Temperature Vacuum Switch (TVS)
1982-83
1. Apply 16 inches Hg to motor side of valve and trap. Cool to test temperature. Switch should hold
vacuum as follows:
a. White TVS--normally open. At 40° F must hold 5 inches Hg for 30 seconds. Should not hold
vacuum above 80° F. b. Brown TVS--normally open. At 5° F must hold 5 inches Hg for 30 seconds.
Should not hold vacuum above 40° F. c. Purple TVS--normally open. At 30° F must hold 5 inches
for 30 seconds. Should not hold vacuum above 60° F. d. Red TVS--normally closed. At 80° F or
higher must hold 5 inches Hg for 30 seconds. Should not hold vacuum below 40° F.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve,
Air Injection > Component Information > Testing and Inspection > Electric PVS High Temp Coolant Lock Out Vacuum >
Page 1508
Thermal Vacuum Valve: Testing and Inspection Thermactor PVS (With 2 Connectors)
PROCEDURE
1. Disconnect both vacuum hoses at PVS valve. Connect vacuum gauge to bottom connector on
PVS.
2. Using an external vacuum source, apply at least 10 inches Hg vacuum to top connector. With
engine cold, there should be no vacuum reading. If
there is, replace PVS.
3. Start engine and allow to reach normal operating temperature. With 10 inches Hg vacuum
applied, there should be a vacuum reading. If not, PVS
is defective and should be replaced.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve,
AIR > Component Information > Testing and Inspection > Thermactor Vacuum Vent Valve
Vacuum Check Valve: Testing and Inspection Thermactor Vacuum Vent Valve
PROCEDURE
1. If necessary, remove air cleaner assembly.
2. Disconnect vacuum tubing or connector block from valve, noting location of tubing.
NOTE: It may be necessary to remove valve from bracket or air cleaner tray to gain access to
vacuum ports on valve.
3. Connect the black vacuum port to a manifold vacuum source.
4. Connect an external vacuum source to white body vacuum port.
5. With engine idling in neutral, apply 10 inches Hg vacuum to white port and trap. If vacuum
cannot be obtained, replace valve.
6. Remove manifold vacuum source line from black port. The trapped vacuum should drop to zero.
If not, replace valve.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve,
AIR > Component Information > Testing and Inspection > Thermactor Vacuum Vent Valve > Page 1514
Vacuum Check Valve: Testing and Inspection Vacuum Check Valve
To check vacuum check valve, use a suitable hand held vacuum pump and apply 16 inches Hg
vacuum to the check portion of valve. Maintain vacuum. If vacuum applied remains above 15
inches Hg vacuum for approximately 10 seconds, the vacuum check valve is operating properly. If
not, replace vacuum check valve.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve,
AIR > Component Information > Testing and Inspection > Thermactor Vacuum Vent Valve > Page 1515
Vacuum Check Valve: Testing and Inspection Vacuum Reservoir Check Valve
NOTE:
This valve is used on some vehicles equipped with catalytic converter.
PROCEDURE
1. Disconnect vacuum hose on reservoir which connects to electric solenoid valve vacuum nipple.
2. Connect a 0-30 inch Hg vacuum gauge to reservoir using a suitable length of hose.
3. Disconnect manifold vacuum hose from reservoir and connect an external vacuum source to the
nipple. Apply 14 inches Hg vacuum to reservoir
and trap. Vacuum reading on gauge should not drop more than 1 inch Hg in one minute. If it does,
replace reservoir.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition
Catalytic Converter: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 1524
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 1525
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 1526
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 1527
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 1528
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 1529
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest for Catalytic Converter: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 1530
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition
Catalytic Converter: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1536
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1537
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1538
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1539
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1540
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1541
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > 95711 > Apr > 95 >
Engine - Lack of Power and/or No Start Condition > Page 1542
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 1543
Catalytic Converter: Description and Operation
Fig.8 - Catalytic Converter With Single Substrate Catalyst
Fig.9 - Catalytic Converter With Dual Substrate Catalyst
The catalytic converter is an emission control device added to the exhaust system to effectively
reduce the levels of carbon monoxide (CO), hydrocarbons (HC), and in some cases oxides of
nitrogen (NOx), entering the atmosphere. The converter permits a faster chemical reaction to take
place and although it enters into the chemical reaction, it remains unchanged, ready to repeat the
process.
The catalyst in these converters is structured in the form of a honeycomb monolithic composition,
Figs. 8 and 9. The catalyst consists of a porous substrate of an inert material, coated with platinum
and other noble metals (the catalytically active materials).
NOTE: Phase II Catalytic Converters or Dual Catalytic Converters which also control the NOx
emissions, are used on some 1978-82 vehicles.
During engine operation, all of the exhaust gases flow through the converter where a chemical
change takes place. This change causes the temperature inside the converter to be higher than the
temperature of the exhaust gases when they leave the engine. Due to this increase in heat, the
converter is insulated so that its outside temperature is about the same temperature as the muffler.
However, due to its solid mass, the converter remains hot much longer than the muffler.
The body of the catalytic converter is made of stainless steel designed to last the life of the vehicle.
Excessive heat can bulge or distort the converter. Since excessive heat built up is not the fault of
the converter, the carburetion or ignition system should be checked whenever a converter is
damaged by overheating.
Although all vehicles with catalytic converter must use unleaded fuel, small amounts of leaded fuel
can be used in case of an emergency. To prevent adding leaded fuel, the fuel tank filler nozzle has
a built-in restrictor.
Heat shields are used on some vehicles to protect chassis components, passenger compartment,
and other areas from heat damage that may be caused by the catalytic converter.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 1544
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 1545
Catalyst and Exhaust Systems
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) >
Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Specifications > Mechanical Specifications
Exhaust Heat Control Valve: Mechanical Specifications
PVS Body Color Opening Temperature
Black 92-98 F
Blue 125-131 F
Purple 157-163 F
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) >
Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Specifications > Mechanical Specifications > Page
1551
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) >
Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Specifications > Page 1552
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Solenoid > Component Information > Description and Operation
Bowl Vent Solenoid: Description and Operation
Fig. 9 Carburetor fuel bowl solenoid vent valve
This valve, Fig. 9, used on some vehicles, is a normally open valve located in the fuel bowl vent
line to the carbon canister. When the engine is running, the valve closes off the fuel bowl vent line.
When the engine is shut off, the vent line returns to the normally open condition.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Solenoid > Component Information > Description and Operation > Page 1557
Bowl Vent Solenoid: Testing and Inspection
Apply 12 volts to valve. The valve should close, allowing no air to pass.
NOTE: If a lean fuel mixture is suspected of causing a problem, inspect either the solenoid vent
valve or the fuel bowl vent valve for proper closing during engine operation. If the valve opens,
allowing purged vacuum to affect fuel bowl balanced air pressure, the carburetor will give a leaner
air/fuel mixture. On EEC equipped engines with a 7200 VV feedback carburetor (back-suction type
only), the opposite (rich mixture) will result from an open or leaking valve.
CAUTION: The utmost care should be exercised when using a torch in the area of the fuel
evaporation system as an open flame near these hoses may cause a fire and ultimate explosion.
NOTE: Vapor line hoses used in these systems are made from a special rubber material. Bulk
service hoses are available for service and will be marked "EVAP". Ordinary fuel hoses should not
be used. They are subject to deterioration and may clog system.
CAUTION: Installation of a fill cap from a non-emission fuel tank will render the system inoperative,
since the non-emission fill cap is vented and the system must be sealed to function properly. Also if
a non-vented fill cap is installed on a conventional tank, the result will be a serious deformation or a
total collapse of the fuel tank.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Valve > Component Information > Description and Operation
Bowl Vent Valve: Description and Operation
Fig. 10 Carburetor fuel bowl thermal vent valve
The thermal vent valve, Fig. 10, used on some vehicles, is a temperature actuated on/off valve,
that is inserted in the carburetor to carbon canister vent line. This valve is closed when the engine
compartment is cold, preventing fuel tank vapors, generated when the fuel tank heats up before the
engine compartment, from being vented through the carburetor bowl.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Valve > Component Information > Description and Operation > Page 1561
Bowl Vent Valve: Testing and Inspection
1. With ambient temperature at or below 90° F, ensure that valve is fully closed.
2. With ambient temperature at or above 120° F, ensure that valve is fully open.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Description and Operation
Canister Purge Control Valve: Description and Operation
Fig.55 - Purge Control Valve
DESCRIPTION
This valve, Fig. 55, is installed on the carbon canister and controls the flow of fuel vapors during
various engine operating modes. The control is provided by a vacuum signal from either the spark
port, EGR port or intake manifold and opens or closes the valve accordingly.
When the engine is off, the vapors from the fuel tank and carburetor fuel bowl are routed through
the purge control valve and into the carbon canister for storage.
During normal cruise conditions, spark port or EGR vacuum is strong enough to open the orifice in
the purge control valve to allow fuel vapors to flow from the carburetor canister through the purge
line to a connection in the PCV tube or into the carburetor spacer. At the same time, the vapors
from the fuel tank are also directed into the purge line.
At idle and low speed cruise conditions, spark port or EGR port vacuum is not strong enough to
open the orifice in the purge control valve so that the fuel vapors are then routed to the carbon
canister.
NOTE: On some vehicles fuel vapors are not purged during low engine speeds because the
additional fuel vapors will affect the fuel air mixture, resulting in a reduction of idle quality and an
increase in exhaust emissions. On vehicles not affected by this purging, manifold vacuum is used
to actuate the purge control valve and control the purging of fuel vapors since spark port or EGR
port vacuum is too weak.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Description and Operation > Page 1565
Canister Purge Control Valve: Testing and Inspection
Fig.63 - Purge Control Valves
Apply 16 inches Hg vacuum to port A. Air should pass between ports B and C.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Description and Operation
Canister Purge Solenoid: Description and Operation
Fig. 52 Canister purge solenoid
This valve, Fig. 52, used on some vehicles, controls the flow of vapors from the carbon canister to
the intake manifold during various engine operating modes. This is a normally closed valve that is
opened by a signal from the electronic engine control assembly to control carbon canister purging.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Air Separator > Component Information > Technical Service Bulletins > Customer Interest for
Evaporative Emissions Air Separator: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble
Evaporative Emissions Air Separator: Customer Interest Fuel System - Stalls/No Start/Hesitation/
Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Air Separator > Component Information > Technical Service Bulletins > Customer Interest for
Evaporative Emissions Air Separator: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page
1577
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Air Separator > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emissions Air Separator: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/
Stumble
Evaporative Emissions Air Separator: All Technical Service Bulletins Fuel System - Stalls/No
Start/Hesitation/ Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emissions Air Separator > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Evaporative Emissions Air Separator: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/
Stumble > Page 1583
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations
Charcoal Canister: Locations
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations > Page 1587
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations > Page 1588
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Technical Service Bulletins > Customer Interest for
Liquid Vapor Separator: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start
Liquid Vapor Separator: Customer Interest Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Technical Service Bulletins > Customer Interest for
Liquid Vapor Separator: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 1597
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Technical Service Bulletins > Customer Interest for
Liquid Vapor Separator: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 1598
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Technical Service Bulletins > Customer Interest for
Liquid Vapor Separator: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 1599
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Liquid Vapor Separator: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start
Liquid Vapor Separator: All Technical Service Bulletins Fuel System - Fuel Starvation and Hard
Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Liquid Vapor Separator: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 1605
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Liquid Vapor Separator: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 1606
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Liquid Vapor Separator: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start > Page 1607
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Thermal Vacuum Valve - EVAP > Component Information > Description and Operation
Thermal Vacuum Valve - EVAP: Description and Operation
Fig. 22 Ported vacuum switches & vacuum control valves
Fig. 23 Electrical vacuum switch
These switches, Figs. 22 and 23, used on some vehicles, control vacuum to emission components
during engine warm-up.The 2-port and 4-port types open when coolant temperature reaches a
predetermined value. The 3-port type switches vacuum from the center to the top or bottom ports.
Electrical switches can be opened or closed until the PVS is fully cycled. All PVS units are
temperature-activated and have a specific opening and closing temperature.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Thermal Vacuum Valve - EVAP > Component Information > Description and Operation > Page 1611
Thermal Vacuum Valve - EVAP: Testing and Inspection
Fig. 22 Ported vacuum switches & vacuum control valves
Fig. 23 Electrical vacuum switch
VACUUM SWITCH TEST
1. With engine cold, turn ignition key to ``ON,'' connect vacuum gauge to port A, Figs. 22 and 23,
and a vacuum source to port B and then C. There
should be no vacuum flow from A to B but there should be vacuum from A to C.
2. Start engine and run until it reaches normal operating temperature, then apply vacuum to port B
and then port C. There should be vacuum from A
to B but no vacuum from A to C. On 4-port valve, check A1 to B1 and A2 to B2 separately.
3. If vacuum flow is not as described, replace valve.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Vacuum Delay Valve, EVAP > Component Information > Description and Operation > Cold Start Spark Hold (CSSH)
Vacuum Delay Valve: Description and Operation Cold Start Spark Hold (CSSH)
This system, used on some vehicles, provides momentary spark advance hold during acceleration
when the engine is cold, to provide improved cold engine acceleration.
When engine coolant temperature is less than 128~ F, the CSSH PVS is closed and the distributor
vacuum signal travels through the restrictor.
When the engine is started cold, high vacuum acts on the vacuum advance unit to provide
maximum advance. During acceleration, the high vacuum in the vacuum advance unit is slowly
bled down through the restrictor, providing a modified vacuum advance during the initial stage of
acceleration.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Vacuum Delay Valve, EVAP > Component Information > Description and Operation > Cold Start Spark Hold (CSSH) > Page
1616
Vacuum Delay Valve: Description and Operation Delay Vacuum Bypass (DVB)
Delay vacuum bypass system - DVB
Some vehicles are equipped with a delay vacuum bypass system as a part of the spark delay
system (SDV).
On all vehicles, Fig. 16, the DVB system is activated by a ported vacuum switch (PVS) and allows
full spark port vacuum to the distributor vacuum advance when coolant is below PVS opening
temperature. The system uses a spark delay valve (SDV), a check valve, and a 4 port PVS. When
closed, the two bottom ports of the PVS are used. After opening, the top two ports are used,
allowing vacuum to be routed through the SDV.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Vacuum Delay Valve, EVAP > Component Information > Description and Operation > Cold Start Spark Hold (CSSH) > Page
1617
Vacuum Delay Valve: Description and Operation Vacuum Delay Valves
Fig. 32 Vacuum delay valve--VDV
This valve, Fig. 32, used on some vehicles, further reduces emissions by delaying the spark
advance during rapid acceleration and by cutting off advance immediately upon deceleration. This
is a one-way valve and will not operate if installed backwards.
On all systems which employ the dual diaphragm distributor, the line which has high vacuum at idle
(normal operating temperature) is connected to the secondary (retard) side of the distributor
vacuum advance unit. This is the connection closest to the distributor cap.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Cold Start Spark Advance System
(CSSA)
Vacuum Delay Valve: Testing and Inspection Cold Start Spark Advance System (CSSA)
NOTE:
If engine is pinging, perform steps 1 thru 4.
1. Connect tachometer and start engine.
CAUTION: Do not leave transmission in drive for more than 15 second while performing steps 2
and 4.
2. With parking brake applied, brake pedal depressed and transmission in drive, accelerate engine
and observe RPM at which spark knock or pinging occurs.
3. Place transmission in neutral and accelerate engine to 1500 RPM to allow transmission to cool.
Repeat this step three times.
4. Disconnect and plug vacuum advance line from distributor. Repeat step 2 to record RPM.
5. If spark knock or pinging reoccurred, stop engine and proceed to next step. If spark knock or
pinging did not reoccur, the CSSA PVS and/or retard delay valve (if used) is faulty. Repair or
replace as necessary.
6. Remove spark delay valve (SDV), or vacuum check valve, or spark delay valve and check as
described further on.
7. Using a T-fitting, connect a vacuum gauge to distributor advance hose and disconnect and plug
vacuum hose from bottom port of Cold Start PVS.
8. With engine idling at normal operating temperature, there should be no vacuum reading. If
vacuum is obtained, the Cold Start PVS should be replaced.
9. Reconnect hose to bottom port of Cold Start PVS and disconnect and plug hose from top port of
Cold Start PVS.
10. On vehicles with a cooling PVS, check vacuum at distributor with engine at normal idle. If
reading is 2 inches Hg or less, the cooling PVS is operating properly. If vacuum reading is greater
than specified, disconnect and plug the top vacuum line from the carburetor to the cooling PVS. If
reading is still greater than specified, the cooling PVS should be replaced.
11. With engine idling in neutral, momentarily open the throttle half way.
12. Observe vacuum gauge for a quick rise and fall as throttle is opened and closed. If vacuum is
obtained, the spark advance system is operating properly. If no vacuum is obtained, check vacuum
line for leakage or obstruction and correct as necessary.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Cold Start Spark Advance System
(CSSA) > Page 1620
Vacuum Delay Valve: Testing and Inspection Delay Vacuum Bypass (DVB)
1. Remove air cleaner.
2. Remove spark delay valve. (Refer to Spark Delay Valve section for test procedure for this unit.)
Replace spark delay valve with a connector. Remove vacuum line at distributor and install a
vacuum line at distributor and install a T-fitting and a vacuum gauge.
3. With transmission in neutral and engine idling at normal operating temperature, open throttle to
1/2 open position.
4. Open and close throttle as noted in Step 3 while watching vacuum reading. A quick rise and fall
should be noted. If vacuum is indicated, check the vacuum lines, evaporative canister purge valve.
T-fitting, and carburetor vacuum port for blockage. Correct as necessary.
5. Turn off engine and replace the spark delay valve (tested before reinstalling as noted in Step 2).
Remove vacuum gauge and T-fitting and replace vacuum hoses.
6. Remove vacuum check valve and test. (Refer to Spark Delay Valve section for test procedure for
this unit). Replace if defective. Reinstall valve.
7. Install a T-fitting between the check valve and the PVS. Connect a vacuum gauge at this point.
8. With transmission in neutral and engine idling at normal operating temperature, open throttle to
1/2 position. Note vacuum reading at steady 1/2 throttle. If reading is 2 inches Hg or less, PVS unit
is good. If more than 2 inches Hg is indicated, PVS is defective and must be replaced.
9. Remove vacuum gauge and return all vacuum lines to original location. Reinstall air cleaner
assembly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Cold Start Spark Advance System
(CSSA) > Page 1621
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Backpressure Transducer > Component Information > Description and Operation
EGR Backpressure Transducer: Description and Operation
Fig.49 - Integral EGR Valve Exhaust Back-pressure Transducer
This valve, Fig. 49, performs the same function as the non-integral back pressure transducer used
on some systems. The valve assembly has an internal exhaust gas chamber with a transducer
diaphragm which senses exhaust back pressure through a hollow stem. When back pressure is
low, vacuum is bled through the transducer valve and the EGR valve stem remains closed. When
back pressure increases, the transducer diaphragm moves up and closes the transducer valve
vacuum bleed hole.
With the vacuum bleed closed, the EGR valve opens, allowing exhaust gas to flow into the intake
manifold. Because the EGR outlet is always exposed to manifold vacuum and EGR gas inlet flow is
restricted by an orifice, back pressure at the transducer drops when the EGR valve opens. When
the back pressure drops, the vacuum bleed hole opens, closing the EGR valve and allowing
pressure to build up again. The cycle is continually repeated, modulating the flow of exhaust gas
into the intake manifold.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Technical Service Bulletins > EGR Solenoids - Contamination
EGR Control Solenoid: Technical Service Bulletins EGR Solenoids - Contamination
Article No. 85-13-5
EGR SOLENOIDS - CONTAMINATION
FORD 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT SOLENOIDS
LINCOLN-MERCURY 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT
SOLENOIDS
The use of starter fluids (ether and xylene), choke and/or fuel injector cleaners, can contaminate
the EGR control and vent solenoids EGRC/EGRY. These solvents may affect the upper elastomer
tip of the solenoid armature, causing an inoperative condition.
Care must also be used to avoid getting these starter fluids into the vacuum harness, and
contaminating these emission components in this way.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Technical
Service Bulletins > EGR Solenoids - Contamination
EGR Vacuum Regulator Solenoid: Technical Service Bulletins EGR Solenoids - Contamination
Article No. 85-13-5
EGR SOLENOIDS - CONTAMINATION
FORD 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT SOLENOIDS
LINCOLN-MERCURY 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT
SOLENOIDS
The use of starter fluids (ether and xylene), choke and/or fuel injector cleaners, can contaminate
the EGR control and vent solenoids EGRC/EGRY. These solvents may affect the upper elastomer
tip of the solenoid armature, causing an inoperative condition.
Care must also be used to avoid getting these starter fluids into the vacuum harness, and
contaminating these emission components in this way.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Technical
Service Bulletins > Page 1634
EGR Vacuum Regulator Solenoid: Locations
LH Side Of V8-302/5.
Attached to LH Valve Cover
Applicable to: 0L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation
EGR Valve: Description and Operation
In this system the exhaust gases are reintroduced to the combustion cycle, therefore diluting the air
fuel mixture entering the combustion chambers. Dilution of the incoming mixture lowers peak flame
temperatures during combustion and thus limits the formation of nitrogen oxides (NOx).
Fig. 46 Spacer entry EGR connection
Some engines use the ``Spacer Entry'' EGR System which has the EGR valve mounted on the
carburetor spacer, Fig. 46. The exhaust gases are taken from a drilled passage in the exhaust
crossover of the intake manifold. The exhaust gas is then routed through a metered EGR valve to a
passage in the carburetor spacer and fed into the primary bore.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 1638
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 1639
Fig. 48 Venturi vacuum amplifier
A Venturi Vacuum Amplifier, Fig. 48, uses a weak venturi vacuum signal to produce a strong intake
manifold vacuum to operate the EGR valve, thereby achieving an accurate, repeatable and almost
exact proportion between venturi airflow and EGR flow. This assists in controlling oxides of
nitrogen with minimal sacrifice in driveability.
There are four basic types of EGR valves: the ported type, the integral back pressure type, the
electronic-sonic type and the valve and transducer assembly type
The electronic-sonic type valve is used with the EEC system.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 1640
Fig. 6 EGR valve position sensor
This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a
reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional
to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold.
Depending on the input from this and other sensors, the computer can increase or decrease EGR
flow by activating or deactivating a pair of solenoid vacuum valves.
Fig. 49 Ported type EGR valves
Ported type valves, Fig. 49, may be of the poppet or tapered stem design and can have base or
side entry. The two passages connecting the exhaust system to intake manifold are blocked by a
valve which is opened by vacuum and closed by spring pressure.
Fig. 50 Integral back pressure transducer EGR valve
The integral back pressure transducer valve, Fig. 50, cannot be opened by vacuum until the bleed
hole is closed by exhaust back pressure. When open, the valve oscillates at a level dependent on
the exhaust back pressure flowing through the orifice. Valve opening increases as signal vacuum
and exhaust back pressure increases.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 1641
Fig. 51 EGR valve w/remote back pressure transducer
Some vehicles use an EGR valve with a remote back pressure transducer, Fig. 51. This assembly
operates the same as the EGR valve with integral back pressure transducer valve and is serviced
only as an assembly.
Some vehicles use a variable transducer type EGR valve and consists of three components; a
vacuum regulator, EGR valve and a flow control orifice. The regulator modulates the vacuum signal
to the EGR valve using two back pressure inputs. One input is the standard vehicle back pressure
and the other is the back pressure down stream of the flow control orifice. The control chamber
pickup is in the EGR tube and the flow control orifice is integral with the upstream EGR tube
connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Locations
EGR Valve Position Sensor: Locations
LH Side Of V8-302/5.
At Center Engine To Rear Of Carburetor
Applicable to: 0L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Exhaust
Pressure Regulator Vacuum Valve, EGR > Component Information > Testing and Inspection
Exhaust Pressure Regulator Vacuum Valve: Testing and Inspection
1. Run engine at normal operating temperature and set throttle on high cam on 4-140 engine or on
kickdown step on other engines.
2. Connect vacuum gauge to EGR side of load control valve and note reading.
3. Apply a vacuum of at least 6 inches Hg to venturi port of valve. If gauge does not drop to zero,
replace valve.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal
Vacuum Valve, EGR > Component Information > Description and Operation
Thermal Vacuum Valve: Description and Operation
Fig. 22 Ported vacuum switches & vacuum control valves
Fig. 23 Electrical vacuum switch
These switches, Figs. 22 and 23, used on some vehicles, control vacuum to emission components
during engine warm-up.The 2-port and 4-port types open when coolant temperature reaches a
predetermined value. The 3-port type switches vacuum from the center to the top or bottom ports.
Electrical switches can be opened or closed until the PVS is fully cycled. All PVS units are
temperature-activated and have a specific opening and closing temperature.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal
Vacuum Valve, EGR > Component Information > Description and Operation > Page 1651
Thermal Vacuum Valve: Testing and Inspection
Fig.50 - EGR-PVS Opening Temperature Chart
Switches With Two Connectors
1. Disconnect both vacuum hoses at switch. Connect a vacuum gauge to either connector on
switch. Connect an external vacuum source at least 10
inches Hg or manifold vacuum to other connector on switch.
2. Start engine and allow coolant to exceed the calibration temperature of the switch as indicated in
chart in Fig. 50, according to color code.
3. If there is no vacuum reading after coolant temperature exceeds the calibration point of the
switch, the PVS switch is defective and should be
replaced. If there is a vacuum reading, the switch is functioning properly.
Switches With Three Connectors
1. Disconnect EGR vacuum hose at carburetor and connect manifold vacuum or external vacuum
source to hose.
2. Disconnect EGR vacuum hose at EGR valve and connect vacuum gauge to hose.
3. Start engine and allow coolant temperature to exceed calibration point of switch as indicated in
chart in Fig. 50, according to color code.
4. There should be a vacuum reading at gauge after coolant temperature exceeds calibration point
of switch. If not, the switch is defective and should
be replaced.
Switches With Four Connectors
1. Disconnect vacuum hoses at PVS valve, then connect a vacuum gauge to either port marked D
and M, and connect an external vacuum source to
other port.
2. Start engine and allow coolant temperature to exceed calibration point of PVS valve as indicated
in Fig. 50, according to color code.
3. If there is a vacuum reading after coolant temperature has exceeded calibration temperature of
PVS valve, valve is defective and should be
replaced. If there is no vacuum reading, that portion of valve is functioning properly.
4. Connect vacuum gauge to either bottom ports marked E and S and other port to vacuum supply.
5. There should be a vacuum reading at gauge with coolant temperature above the calibration point
of the PVS valve. If not, the PVS valve is
defective and should be replaced.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Description and Operation
Positive Crankcase Ventilation Valve: Description and Operation
Fig. 62 Typical PCV system
Fig. 63 Typical PCV valve
All engines produce small amounts of blowby gases which seep past the piston rings and into the
crankcase. These blowby gases are the result of the high pressures developed within the
combustion chamber during the combustion process, and contain undesirable pollutants. To
prevent blow-by gases from entering atmosphere while allowing proper crankcase ventilation, all
engines use a PCV system, Fig. 62.
The PCV system prevents blowby gases from escaping by routing them through a vacuum
controlled ventilating valve and a hose into the intake manifold. The blowby gases mix with the
air/fuel mixture and are burned in the combustion chambers. When the engine is running, fresh air
is drawn into the crankcase through a tube or hose connected to the air cleaner housing.
The PCV valve, Fig. 63, consists of a needle valve, spring and housing. When the engine is off, the
spring holds the needle valve closed to stop vapors from entering the intake manifold. When the
engine is running, manifold vacuum unseats the valve allowing crankcase vapors to enter the
intake manifold. In case of a backfire in the intake manifold, the valve closes, stopping the backflow
and preventing ignition of fumes in the crankcase. During certain engine conditions, more blowby
gases are created than the ventilator valve can handle. The excess is returned through the air
intake tube to the air cleaner and carburetor where it is burned in the engine.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Page 1656
Positive Crankcase Ventilation Valve: Testing and Inspection
1. Pull end of PCV valve out of valve cover. If valve rattles when shaken, proceed to step 2. If not,
replace valve.
2. Disconnect vacuum hose from air cleaner and feel for vacuum at hose with engine at idle. If
vacuum is felt, system is satisfactory. If no vacuum is felt, check for obstructions in PCV system or
a leaking evaporative valve.
3. Disconnect evaporative hose, then cap the tee fitting and retest. If vacuum is now felt, PCV
system is satisfactory. Check evaporative system. If no vacuum is felt, check for vacuum back
through the system and inspect rocker cover gasket for leaks. Repair or replace components as
necessary.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Locations
EGR Valve Position Sensor: Locations
LH Side Of V8-302/5.
At Center Engine To Rear Of Carburetor
Applicable to: 0L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <-->
[Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and
Operation > Auxiliary Air Inlet Valve
Thermostatic Air Cleaner Vacuum Switch: Description and Operation Auxiliary Air Inlet Valve
Fig.5 - Auxiliary Air Inlet Valve
The auxiliary air inlet valve is mounted on the outside of the air cleaner housing and serves to allow
outside air to bypass the heated air inlet system when the engine is under load. When manifold
vacuum is low, a spring in the vacuum motor allows the valve to open, providing an additional flow
of air into the air cleaner housing, Fig. 5.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <-->
[Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and
Operation > Auxiliary Air Inlet Valve > Page 1666
Thermostatic Air Cleaner Vacuum Switch: Description and Operation Cold Weather Modulator
Fig.4 - Cold Weather Modulator
This modulator, Fig. 4, located in the air cleaner housing of some 1975-82 Ford vehicles, prevents
the air cleaner door from opening to non-heated outside air at ambient temperatures below 55° F.
At ambient temperatures above 55° F., the modulator is inoperative. During acceleration at ambient
temperatures below 55° F., the modulator located in-line between the bi-metal sensor and vacuum
duct motor, will close off vacuum to the motor and hold the duct open.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <-->
[Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and
Operation > Page 1667
Thermostatic Air Cleaner Vacuum Switch: Testing and Inspection
Procedure
1. Cool modulator to below 40° F (except black modulator) or 20° F (black modulator). Allow
enough time for modulator temperature to stabilize
and modulator valve to close.
2. On 1975-76 systems, use an external vacuum source and apply at least 16 inches Hg vacuum to
vacuum motor side and trap vacuum by pinching
hose. Modulator must hold at least 14 inches Hg vacuum for 60 seconds. If not, replace modulator.
3. On 1977-80 systems, use a 24 inch length of 1/4 inch hose between cold weather modulator and
vacuum gauge. Using an external vacuum source,
apply at least 16 inches Hg vacuum to vacuum motor side of modulator and trap vacuum by
pinching hose. The modulator must hold at least 5 inches Hg vacuum for 30 seconds. If not,
replace modulator.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vacuum Restrictor > Component
Information > Description and Operation
Vacuum Restrictor: Description and Operation
Fig.30 - Vacuum Restrictor
The orifice type flow restrictor, Fig. 30, is used on some systems to control the flow rate and or
timing characteristics to the following systems:
a. EGR valve timing (opening and closing).
b. Part throttle spark advance.
c. Purge system.
d. Thermactor system
The flow rate through the restrictor is the same in both directions. If blocked, it should be replaced.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications
Fuel Pressure: Specifications
Fuel Pump Pressure (Mechanical) ......................................................................................................
........................................................... 6-8 psi (at idle) Fuel Pump Pressure (Electrical) .....................
.............................................................................................................................................................
4.3 psi
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications > Page 1675
Fuel Pressure: Testing and Inspection
1. Connect a suitable pressure gauge (0-15 psi) to the carburetor end of the fuel line (no "T" is
required). 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. The fuel
pump pressure should read 6-8 psi at normal curb idle speed, with the transmission in NEUTRAL,
the engine at normal operating temperatures, and the fuel return line closed (if present). If pump
pressure is too low or too high install a new fuel pump.
3. Reconnect fuel line at filter and install air cleaner.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications
Idle Speed: Specifications
Curb Idle Speed ...................................................................................................................................
................................................ 650 rpm (in DRIVE)
Fast Idle Speed ...................................................................................................................................
........................................... 1600 rpm (in PARK) [1]
[1] On high step of fast idle cam.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure
Air Cleaner Housing: Technical Service Bulletins Air Cleaner - Sealing Procedure
Article No. 83-25-21-S
AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS
WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD
CONDITIONS ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED
LIGHT TRUCKS 1980-83 E, F AND BRONCO
This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the
TSB are of insufficient detail and are therefore being deleted from the TSB.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB.
See your normal parts listing for these part numbers.
The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing
concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles,
a poor running condition. The following procedure should minimize these concerns.
1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the
tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light
trucks except the 1983 Econoline with the 4.9L engine.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB.
See your normal parts listings for these part numbers.
2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that
would prevent a good seal. Replace any damaged components.
3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped
or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the
carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure
a tight bond.
Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A.
FIGURE 24
4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the
radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure
the zip tube to the top of the housing with a nylon tie-down
strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be
reinstalled to the radiator support. 5.
Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in
the air cleaner with an in-line filter.
a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in
the air cleaner, the adapter at the air cleaner and the adapter retaining clip.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1683
b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing
crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does
not need a new hole).
c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs.
2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L).
d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L
and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.).
NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking
into the end of the filter assembly.
e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S.
Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter
(closure) pack hole for 4.9L.
f. Cut the PCV filter (closure) hose to proper length and attach to the adapter.
g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only.
FIGURE 25
6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent
dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25).
a. Remove the carburetor from the vehicle.
b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or
equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the
carburetor. Pay particular attention to the top and bottom of the upper body casting around the
choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air.
c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body
casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper
motor at this time.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1684
FIGURE 24
d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a
toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning
"Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24).
Fill the hole completely around the rods from the top side only and release the throttle lever.
e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off"
position so that choke rod is fully raised. Fast idle cam should remain in "off" position.
f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft
rod. Fill the hole completely around the rod from the bottom side only.
g. Install the spring, pintle, gasket, and stepper motor.
h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV.
i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free)
accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper
body.
j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV
sealant should remain attached to upper body.
k. Re-install carburetor on vehicle.
7. Re-install and secure the air cleaner assembly as follows:
a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray
seating securely and completely sealing the flange.
b. Connect and secure the vacuum hoses.
c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for
4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L.
NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine.
d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing
nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing
to the carburetor is assured.
e. Connect the crankcase filter hose securely.
f. Install the heat riser tube. Connect the fresh air zip tube.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1685
Obtain an Authorized Modifications decal and list the date, dealer number and summary of
alterations performed. Select a prominent place adjacent to the Vehicle Emission Control
Information decal suitable for installing the Authorized Modifications decal. Clean the area, install
the decal and cover it with a clear plastic decal shield. PART NUMBER
PART NAME CLASS
E2AZ-6A768-A PCV Filter C
E2AZ-6853-A 1/2" PCV Hose C
E43Z-9E606-A Adapter C
E2TZ-9601-B Air Filter Element AM
E0TZ-9601-A Air Filter Element AM
C6TZ-9697-A Washer AM
D8ZZ-9654-A Gasket A
377678-S Plug BR
E3AZ-19562-A RTV Sealer A
390013-S36B Wing Nut S
C8DZ-9654-A Gasket AM
OTHER APPLICABLE ARTICLES: 83-25-21 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP9600C84 TIME:
6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition
Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1694
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1695
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1696
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1697
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1698
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1699
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1700
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Lack of Power and/or No
Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1706
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1707
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1708
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1709
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1710
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1711
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 1712
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump >
Component Information > Description and Operation > Page 1717
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump >
Component Information > Adjustments > Component Adjustment Specifications
1982 4180-C 4V ADJUSTMENT SPECIFICATIONS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump >
Component Information > Adjustments > Component Adjustment Specifications > Page 1720
Accelerator Pump: Adjustments Accelerator Pump Level
Fig. 6 Checking accelerator pump lever clearance
1. Using a feeler gauge and with throttle plates wide open, there should be the specified clearance
(minimum) between pump operating lever adjustment screw and pump arm when pump arm is
depressed manually, Fig.6.
2. If adjustment is required, loosen lock nut and turn adjusting screw in to increase clearance and
out to decrease clearance. One-half turn of screw is equal to approximately .015 inch.
3. When proper adjustment has been made, hold screw in position with a wrench and tighten lock
nut.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump >
Component Information > Adjustments > Component Adjustment Specifications > Page 1721
Accelerator Pump: Adjustments Accelerator Pump Stroke
To satisfy the requirements in various climates, the pump discharge can be adjusted. The bottom
hole (No. 2) in the pump cam and throttle lever provides the maximum pump discharge for extreme
cold weather, and the top hole (No. 1) provides the minimum pump discharge for warm weather
operation. If a change in the adjustment is required, make certain the proper hole in plastic pump
cam, located behind throttle lever, is properly indexed with the numbered hole in the throttle lever
before installing the retaining screw.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid >
Component Information > Description and Operation
Bowl Vent Solenoid: Description and Operation
Fig. 9 Carburetor fuel bowl solenoid vent valve
This valve, Fig. 9, used on some vehicles, is a normally open valve located in the fuel bowl vent
line to the carbon canister. When the engine is running, the valve closes off the fuel bowl vent line.
When the engine is shut off, the vent line returns to the normally open condition.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid >
Component Information > Description and Operation > Page 1725
Bowl Vent Solenoid: Testing and Inspection
Apply 12 volts to valve. The valve should close, allowing no air to pass.
NOTE: If a lean fuel mixture is suspected of causing a problem, inspect either the solenoid vent
valve or the fuel bowl vent valve for proper closing during engine operation. If the valve opens,
allowing purged vacuum to affect fuel bowl balanced air pressure, the carburetor will give a leaner
air/fuel mixture. On EEC equipped engines with a 7200 VV feedback carburetor (back-suction type
only), the opposite (rich mixture) will result from an open or leaking valve.
CAUTION: The utmost care should be exercised when using a torch in the area of the fuel
evaporation system as an open flame near these hoses may cause a fire and ultimate explosion.
NOTE: Vapor line hoses used in these systems are made from a special rubber material. Bulk
service hoses are available for service and will be marked "EVAP". Ordinary fuel hoses should not
be used. They are subject to deterioration and may clog system.
CAUTION: Installation of a fill cap from a non-emission fuel tank will render the system inoperative,
since the non-emission fill cap is vented and the system must be sealed to function properly. Also if
a non-vented fill cap is installed on a conventional tank, the result will be a serious deformation or a
total collapse of the fuel tank.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Float >
Component Information > Specifications
1982 4180-C 4V ADJUSTMENT SPECIFICATIONS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Float >
Component Information > Adjustments > Float Level (Dry)
Carburetor Float: Adjustments Float Level (Dry)
Fig. 4 Float adjustment
The dry float adjustment is a preliminary fuel level adjustment only. The final adjustment must be
performed after the carburetor is installed on the engine. With fuel bowl and float removed, adjust
the float so that it is parallel to the fuel bowl with the top of the fuel bowl inverted, Fig. 4. Adjust
both sides in the same manner.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Float >
Component Information > Adjustments > Float Level (Dry) > Page 1731
Carburetor Float: Adjustments Fuel Level (Wet)
Fig. 5 Fuel level adjustment
1. With vehicle resting on a flat surface, operate engine until normal operating temperature is
reached.
2. Remove air cleaner, then operate engine at approximately 1000 rpm for 30 seconds to stabilize
fuel level.
3. Stop engine, then remove sight plug from side of primary carburetor bowl.
4. Fuel level should be at bottom of sight plug hole. If fuel level is below sight plug hole, raise fuel
level. If fuel overflows when plug is removed, lower fuel level. Never loosen lock screw or nut or
attempt to adjust fuel level with sight plug removed or engine running, as this will create a potential
fire hazard.
5. Adjust fuel level as necessary by loosening lock screw, then turning adjusting nut clockwise to
lower fuel level or counterclockwise to raise fuel level, Fig. 5. Tighten lock screw and install sight
plug, using old gasket, then run engine at 1000 RPM for approximately 30 seconds to stabilize fuel
level. Each 1/8 turn of the adjusting nut will change fuel level approximately 1/32 inch.
6. Stop engine, remove sight plug and recheck fuel level. Repeat step 5 until fuel level is at bottom
of sight plug hole, then reinstall sight plug using a new gasket.
7. Perform steps 3 through 6 for secondary fuel bowl. To stabilize fuel level in the secondary fuel
bowl, the secondary throttle must be used.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Intake
Manifold Spacer > Component Information > Technical Service Bulletins > Customer Interest for Carburetor Intake Manifold
Spacer: > 882020 > Sep > 88 > Engine - Poor Performance/Spark Knock/Exhaust Backfire
Carburetor Intake Manifold Spacer: Customer Interest Engine - Poor Performance/Spark
Knock/Exhaust Backfire
Article No. 88-20-20
09/23/88
^ PERFORMANCE POOR - 6.1L, 7.0L AND 7.5L 4V ENGINES
^ SPARK KNOCK - 6.1L, 7.0L AND 7.5L 4V ENGINES
^ BACKFIRE - 6.1L, 7.0L AND 7.5L 4V ENGINES
LIGHT TRUCK: 1979-87 E AND F-SERIES
ISSUE: Poor performance, spark knock and exhaust backfire may be caused by a burned out or
blown out EGR spacer-to-intake manifold gasket. The damaged gasket causes exhaust gas and
intake manifold vacuum leaks which results in one or all of the above driveability conditions.
ACTION: Install a new EGR spacer-to-intake manifold gasket that has long life durability under high
heat conditions. Refer to the following procedure for service details.
1. Remove the air cleaner.
2. Remove the throttle rod from the throttle lever on 6.1L and 7.0L engines or the throttle cable on
7.5L engines.
3. Disconnect the choke control cable on 6.1L and 7.0L engines only.
4. Disconnect the hand ihrottle control cable on 6.1L and 7.0L engines only.
5. Disconnect and label the vacuum hoses for the distributor and EGR valve. Also disconnect the
vacuum hose at the governor on 6.1L and 7.0L engines only.
6. Disconnect the PCV hose.
7. Disconnect the carburetor fuel line.
8. Disconnect the governor electrical connector on 6.1L and 7.0L engines only.
9. Remove the carburetor retaining nuts and lock washers.
10. Remove the carburetor and EGR spacer from the intake manifold.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Intake
Manifold Spacer > Component Information > Technical Service Bulletins > Customer Interest for Carburetor Intake Manifold
Spacer: > 882020 > Sep > 88 > Engine - Poor Performance/Spark Knock/Exhaust Backfire > Page 1740
11. Remove the EGR spacer-to-intake manifold gasket and the carburetor-to-EGR spacer gasket
and throw them away, Figure 14.
12. Thoroughly clean gasket mating surfaces and install a new service EGR spacer-to-intake
manifold gasket, (E8TZ-9447-A) and carburetor-to-EGR spacer gasket, (E5HZ-9C477-B).
13. Reverse Steps 1 through 11 for assembly.
14. Adjust the engine idle speed.
15. Adjust the primary and secondary fuel levels and idle fuel mixture.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Emissions Warranty Coverage
OPERATION: 882020A
TIME: 1.1 Hrs. DLR. CODING: Basic Part No. 9447 Condition Code: 74
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Intake
Manifold Spacer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carburetor
Intake Manifold Spacer: > 882020 > Sep > 88 > Engine - Poor Performance/Spark Knock/Exhaust Backfire
Carburetor Intake Manifold Spacer: All Technical Service Bulletins Engine - Poor
Performance/Spark Knock/Exhaust Backfire
Article No. 88-20-20
09/23/88
^ PERFORMANCE POOR - 6.1L, 7.0L AND 7.5L 4V ENGINES
^ SPARK KNOCK - 6.1L, 7.0L AND 7.5L 4V ENGINES
^ BACKFIRE - 6.1L, 7.0L AND 7.5L 4V ENGINES
LIGHT TRUCK: 1979-87 E AND F-SERIES
ISSUE: Poor performance, spark knock and exhaust backfire may be caused by a burned out or
blown out EGR spacer-to-intake manifold gasket. The damaged gasket causes exhaust gas and
intake manifold vacuum leaks which results in one or all of the above driveability conditions.
ACTION: Install a new EGR spacer-to-intake manifold gasket that has long life durability under high
heat conditions. Refer to the following procedure for service details.
1. Remove the air cleaner.
2. Remove the throttle rod from the throttle lever on 6.1L and 7.0L engines or the throttle cable on
7.5L engines.
3. Disconnect the choke control cable on 6.1L and 7.0L engines only.
4. Disconnect the hand ihrottle control cable on 6.1L and 7.0L engines only.
5. Disconnect and label the vacuum hoses for the distributor and EGR valve. Also disconnect the
vacuum hose at the governor on 6.1L and 7.0L engines only.
6. Disconnect the PCV hose.
7. Disconnect the carburetor fuel line.
8. Disconnect the governor electrical connector on 6.1L and 7.0L engines only.
9. Remove the carburetor retaining nuts and lock washers.
10. Remove the carburetor and EGR spacer from the intake manifold.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Intake
Manifold Spacer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carburetor
Intake Manifold Spacer: > 882020 > Sep > 88 > Engine - Poor Performance/Spark Knock/Exhaust Backfire > Page 1746
11. Remove the EGR spacer-to-intake manifold gasket and the carburetor-to-EGR spacer gasket
and throw them away, Figure 14.
12. Thoroughly clean gasket mating surfaces and install a new service EGR spacer-to-intake
manifold gasket, (E8TZ-9447-A) and carburetor-to-EGR spacer gasket, (E5HZ-9C477-B).
13. Reverse Steps 1 through 11 for assembly.
14. Adjust the engine idle speed.
15. Adjust the primary and secondary fuel levels and idle fuel mixture.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Emissions Warranty Coverage
OPERATION: 882020A
TIME: 1.1 Hrs. DLR. CODING: Basic Part No. 9447 Condition Code: 74
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Solenoid >
Component Information > Locations
Carburetor Solenoid: Locations
RH Side Of V8-302/5.
RH Side Of Engine
Applicable to: 0L & V8-351/5.8L California Engines w/EEC
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Housing >
Component Information > Technical Service Bulletins > Electric Choke System - Testing Tool
Choke Housing: Technical Service Bulletins Electric Choke System - Testing Tool
Article No: 82-10-13 May 24, 1982
Subject: Rotunda Choke Cap Tester No. 90-0001
FORD All Vehicles With Single - And Two-stage Electric Chokes
LINCOLN-MERCURY All Vehicles With Single - And Two-stage Electric Chokes
The tool was recently released to improve performance and reduce diagnosis time when servicing
choke systems.
Testing time has been reduced to a few minutes with the all electric two-stage choke system. The
temperature range of the tester is from -1 °F to 165 °F. For optimum tool performance, shop air
with a line pressure of 90 PSI with 6-8 C.F.M. volume is required.
An adaptor is provided to service older model single-stage and hot-air-only systems. The unit is
also recommended for testing other heat sensitive/actuated components and auto/temp control
systems.
Refer to the Engine/Emission/Diagnosis Manual and the Manufacturers Instruction Manual
(provided) for procedures and instructions.
Warranty Status: Information Only
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Plate >
Component Information > Adjustments
Choke Plate: Adjustments
Fig. 11 Dechoke adjustment
1. Hold throttle in wide open throttle position.
2. Apply a light closing pressure on the choke plate and measure the gap between the lower edge
of the choke plate and air horn wall.
3. To adjust, bend the pawl on the fast idle lever, Fig. 11, forward to increase or backward to
decrease the clearance.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Pull-off >
Component Information > Specifications
1982 4180-C 4V ADJUSTMENT SPECIFICATIONS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke
<--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Alternator - Replacement
Precautions
Electric Assist Choke: Technical Service Bulletins Alternator - Replacement Precautions
Article No. 85-12-24
RICH MIXTURE - CHOKE DOES NOT OPEN - ELECTRIC CHOKE CONNECTION TO NON-OEM
ALTERNATOR
LIGHT TRUCK ALL SERIES
Replacement of the OEM alternator to accomodate higher current requirements of vehicle-mounted
electrical equipment may adversely affect the operation of the electric choke on those vehicles so
equipped. For this reason, it is important to examine the electrical system on a subject vehicle to
determine if an electric choke is connected to the OEM alternator stator terminal. If there is such a
connection, a similar connection must be provided on the replacement alternator.
Contact the manufacturer of the replacement alternator to determine the correct method of
connecting to the alternator stator.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke
<--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Page 1764
Electric Assist Choke: Description and Operation
Fir. 38 - Typical Electric Assist Choke Installation
Fig.39 - Electric Assist Choke Wiring Schematic
Purpose
Most 1973-82 models are equipped with an electric assist choke to reduce hydrocarbon (HC) and
carbon monoxide (CO) emissions during starting and warm-up--choke on--period.
The electric assist choke is designed to give a more rapid choke opening at temperatures of about
60° to 65° F, or higher. It also provides a slower choke opening at temperatures below this point.
Operation
Current is constantly supplied to the ambient temperature switch. The system is grounded through
a ground strap connected to the carburetor body. At temperatures below approximately 60
degrees, the switch opens and no current is supplied to the ceramic heater located within the
thermostatic spring. Normal thermostatic spring choking action then occurs.
At temperatures above approximately 60-65 degrees, the temperature sensing switch closes and
current is supplied to the ceramic heater. As the heater warms, it causes the thermostatic spring to
pull the choke plates open within 1-1/2 minutes.
The electric assist choke system does not change any carburetor service procedures and cannot
be adjusted.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke
<--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Page 1765
If system is found out of calibration the heater control switch and/or choke unit must be replaced.
Construction
The electric choke system, Figs. 38 and 39, consists of a choke cap, thermostatic spring, a bimetal
temperature sensing disc (switch), and a ceramic positive temperature coefficient (PTC) heater.
The choke is powered from terminal or tap of the alternator.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke
<--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Page 1766
Electric Assist Choke: Testing and Inspection
Procedure
1. Disconnect stator lead at connector leading from choke cap and connect a test light in series
with stator lead and ground.
2. With engine running, test light should glow.
3. If light does not glow, repair or replace either the alternator or choke wire.
4. With engine running at normal operating temperature, place test light in series with choke
terminal and alternator lead. If light does not glow,
replace choke cap assembly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke
<--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Page 1767
Electric Assist Choke: Adjustments
1. Loosen thermostatic spring housing clamp retaining screws.
2. Rotate spring housing to align index mark on spring housing with center index mark on choke
housing.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Needle And Seat,
Carburetor > Component Information > Technical Service Bulletins > Carburetor - Needle and Seat Thread Damage
Needle And Seat: Technical Service Bulletins Carburetor - Needle and Seat Thread Damage
Article No: 82-17-20
08/26/82
Damaged Carburetor Threads
Light Trucks 1979-82 E & F Series With 460 CID Gasoline Engines
Medium/Heavy Trucks 1978-82 B, C, F And L Series Equipped With Gasoline Engines
This article provides carburetor fuel level adjustment procedures to prevent damage to the
carburetor fuel inlet threads.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Needle And Seat,
Carburetor > Component Information > Technical Service Bulletins > Carburetor - Needle and Seat Thread Damage > Page
1772
Figure 23
Damaged threads at the fuel bowl inlet needle and seat can be caused by overtightening the lock
nut on Motorcraft service replacement inlet needle and seat assemblies. (See Figure 23 to identify
Motorcraft verses original Holley style inlet needle and seat assembly.) The proper installation of
the Motorcraft inlet needle and seat is as follows:
1. Install and adjust needle and seat to provide correct fuel level.
2. Tighten lock nut until nut contacts fuel bowl surface. Tighten an additional 1/8 turn, or a torque
value of 15-20 inch pounds.
NOTE:
These procedures apply to Motorcraft service replacement inlet needle and seat assemblies for all
Holley 2V and 4V carburetors that are equipped with externally adjustable inlet needle and seat.
OTHER APPLICABLE ARTICLES: None
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Needle And Seat,
Carburetor > Component Information > Technical Service Bulletins > Carburetor - Needle and Seat Thread Damage > Page
1773
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Throttle Plate - Carb. >
Component Information > Adjustments
Throttle Plate - Carb.: Adjustments
Fig. 7 Secondary throttle plate adjustment
With secondary throttle plates closed, rotate secondary throttle shaft lever stop screw
counter-clockwise until the secondary throttle plates seat in the bores. Rotate adjusting screw
clockwise until it contacts the secondary lever, Fig. 7. Turn stop screw an additional 1/4 turn on
1982 - 84 models or 3/8 turn on 1985 - 87 models.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information
> Adjustments
Dashpot: Adjustments
1. With engine at normal operating temperature, apply 19 inches Hg vacuum to decel throttle
modulator.
2. Loosen decel throttle modulator lock nut and rotate modulator to achieve 1800 RPM.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Rotunda Gas Chek Kit - Requires Modification
Fuel: Technical Service Bulletins Rotunda Gas Chek Kit - Requires Modification
Article No. FUEL SYSTEM - ROTUNDA "GAS-CHEK" KIT 87-23-9 TOOL MODIFICATION
FORD: 1988 And Prior ALL CAR LINES
LINCOLN-MERCURY: 1988 And Prior ALL CAR LINES
LIGHT TRUCK: 1988 And Prior ALL LIGHT TRUCK LINES
ISSUE: The Rotunda "Gas-Chek Kit" (Tool Number 113-00002) that you may have purchased prior
to October, 1987 requires modification. The necessary components and new operating instructions
will be shipped to you at no charge. This tool modification will provide greater accuracy when
performing high fuel vapor pressure testing of gasoline.
ACTION: To modify the Rotunda "Gas-Chek Kit", use the following service instructions.
NOTE: This modification MUST be done because it will seriously affect the volatility tests.
Figure 11
1. Remove adapter fitting attached to the 0-30 PSI gauge. CARE SHOULD BE TAKEN TO
PREVENT DAMAGE TO GAUGE ASSEMBLY WHEN REMOVING FITTING. Throw away the
adapter fitting, Figure 11.
2. Remove and throw away the aluminum vial, Figure 11.
3. Remove plastic thermos cup cap and throw away, Figure 11.
4. Remove the set of instructions from the lid of the Gas-Chek plastic storage box and throw them
away.
NOTE: USE ONLY THE NEW instruction booklet that is furnished in the modification kit.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Rotunda Gas Chek Kit - Requires Modification > Page 1784
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start
Fuel Filter: Customer Interest Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start >
Page 1793
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start >
Page 1794
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Technical Service Bulletins > Customer Interest: > 851519 > Jul > 85 > Fuel System - Fuel Starvation and Hard Start >
Page 1795
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start
Fuel Filter: All Technical Service Bulletins Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 1801
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 1802
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 851519 > Jul > 85 > Fuel System - Fuel
Starvation and Hard Start > Page 1803
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 85610 > Mar > 85 > Fuel Filter Replacement Information
Fuel Filter: All 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Fuel Filter: > 85610 > Mar > 85 > Fuel Filter - Replacement
Information
Fuel Filter: All 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component
Information > Technical Service Bulletins > Fuel Filter - Replacement Information
Fuel Hose Clamp: Technical Service Bulletins Fuel Filter - Replacement Information
Article No. 85-6-10
FUEL FILTER REPLACEMENT INFORMATION - ALL WITH FUEL FILTERS ATTACHED TO THE
CARBURETOR AND/OR FUEL LINE WITH A RUBBER HOSE
FORD ALL 1985 AND PRIOR
LINCOLN-MERCURY ALL 1985 AND PRIOR
LIGHT TRUCK ALL 1985 AND PRIOR
New fuel connector hoses and clamps should be used whenever a fuel filter is replaced.
Due to possible deterioration of hose materials which may result if a vehicle is fueled with gasoline
containing excessive levels of methanol or ethanol, a new fuel hose and clamps should be installed
when the fuel filter is changed. DO NOT REUSE OLD HOSES OR CLAMPS.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications
Fuel Pressure: Specifications
Fuel Pump Pressure (Mechanical) ......................................................................................................
........................................................... 6-8 psi (at idle) Fuel Pump Pressure (Electrical) .....................
.............................................................................................................................................................
4.3 psi
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications > Page 1821
Fuel Pressure: Testing and Inspection
1. Connect a suitable pressure gauge (0-15 psi) to the carburetor end of the fuel line (no "T" is
required). 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. The fuel
pump pressure should read 6-8 psi at normal curb idle speed, with the transmission in NEUTRAL,
the engine at normal operating temperatures, and the fuel return line closed (if present). If pump
pressure is too low or too high install a new fuel pump.
3. Reconnect fuel line at filter and install air cleaner.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Fuel Hoses - Special Material
Fuel Supply Line: Technical Service Bulletins Fuel Hoses - Special Material
Article No. 83-4-27
FUEL SYSTEM SPECIAL FUEL HOSE MATERIAL USED WITH ELECTRIC FUEL PUMP
SYSTEMS IN OVER 8500 LB. GVW LIGHT TRUCKS - SERVICE REPLACEMENT
LIGHT TRUCKS 1980/83 F SERIES AND ECONOLINE
Fuel hoses on vehicles equipped with electric fuel pumps are made of a special fluro elastomer
material that provides longer life when used in the vapor return system environment. Any service
replacement of fuel hoses on these vehicles must use the same type of material. The proper part
numbers of these hoses are listed below:
^ 5/16 I.D. Part Number E0TZ-9324-A Stripe Color Yellow
^ 3/8 I.D. Part Number E0TZ-9324-B Stripe Color Red
NOTE: Service kits installed to prevent vapor locking on 1980/82 over 8500 lb. GVW E/F Series
vehicles also contained fluro elastomer hose and must be serviced with the same service hoses.
PART NUMBER PART NAME CLASS
E0TZ-9324-A 5/16" Fuel Hose C
E0TZ-9324-B 3/8" Fuel Hose C
OTHER APPLICABLE ARTICLES: 82-14-21 WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector
Switch > Component Information > Locations
Fuel Tank Selector Switch: Locations
LH Side Of I/P Near Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Switching Valve: >
831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble
Fuel Tank Switching Valve: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Switching Valve: >
831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1838
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Switching
Valve: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble
Fuel Tank Switching Valve: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/
Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Switching
Valve: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1844
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Technical Service Bulletins > Page 1845
Fuel Tank Switching Valve: Locations
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve
Idle Speed Vacuum Solenoid Valve: Locations Throttle Kicker Vacuum Valve
RH Side Of V8-460/7.
Top Of 8 Cyl. Engine, LH Side of 6 Cyl. Engine
Applicable to: 5L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve >
Page 1851
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non
Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator
Idle/Altitude Compensator (Non Comp. Controlled): Description and Operation Altitude
Compensator
Fig. 7 Electrical type altitude compensator
ELECTRICAL The electrical type altitude compensator, Fig. 7, used on some vehicles, is mounted
on the ignition module. The compensator improves emissions and aids engine performance at
altitudes above 4000 ft. by advancing the timing and leaning the air/fuel mixture.
Fig. 8 Mechanical type altitude compensator
MECHANICAL The mechanical type altitude compensator, Fig. 8, is mounted on the bulkhead. The
compensator leans the air/fuel mixture at altitudes above 3000 ft. by supplying additional filtered air
to the carburetor.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non
Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator > Page 1856
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non
Comp. Controlled) > Component Information > Description and Operation > Page 1857
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <-->
[Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 831112S > Sep
> 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble
Fuel Pump Inertia Switch: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <-->
[Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > Customer Interest: > 831112S > Sep
> 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1866
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <-->
[Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble
Fuel Pump Inertia Switch: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/
Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <-->
[Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: >
831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1872
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <-->
[Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel
Pump Inertia Switch: > NHTSA82V104000 > Oct > 82 > recall 82V104000: Rear Axle Nut Inspection
Axle Nut: All Technical Service Bulletins recall 82V104000: Rear Axle Nut Inspection
ON CERTAIN VEHICLES, THE LOCK WEDGES USED TO SECURE THE AXLE BEARING NUTS
TO THE AXLE HOUSING MAY FALL OUT OF POSITION, ALLOWING THE NUT TO LOOSEN.
THE NUT ON THE LEFT SIDE MAY FALL OFF, ALLOWING MOVEMENT OF THE AXLE SHAFT.
THE DEALER WILL REPLACE DEFECTIVE LOCK WEDGES WITH AN IMPROVED VERSION.
WHEEL BEARINGS WILL BE INSPECTED AND ADJUSTED OR REPLACED, IF NECESSARY.
VEHICLE DESCRIPTION: LIGHT TRUCKS WITH DANA FULL-FLOATING REAR AXLES.
SYSTEM: POWER TRAIN; REAR AXLE ASSEMBLY. CONSEQUENCES OF DEFECT: THIS
COULD RESULT IN PARTIAL LOSS OF BRAKING ACTION OR PARTIAL OR TOTAL
SEPARATION OF THE LEFT REAR WHEEL AND BRAKE ASSEMBLY.IN EITHER CASE, LOSS
OF VEHICLE CONTROL AND AN ACCIDENT COULD FOLLOW.
1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK F250 1982 FORD
TRUCK F350 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK F250
1983 FORD TRUCK F350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
RH Fender Apron w/EEC
Attached To Top Of RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 1886
Main Relay (Computer/Fuel System): Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
RH Fender Apron w/EEC
Attached To Top Of RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 1891
Main Relay (Computer/Fuel System): Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations
Fuel Tank Selector Switch: Locations
LH Side Of I/P Near Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > Customer Interest: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble
Fuel Pump Inertia Switch: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > Customer Interest: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble
> Page 1904
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 831112S > Sep > 84 > Fuel System - Stalls/No
Start/Hesitation/ Stumble
Fuel Pump Inertia Switch: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/
Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 831112S > Sep > 84 > Fuel System - Stalls/No
Start/Hesitation/ Stumble > Page 1910
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Inertia Switch: > 851519 > Jul > 85 > Fuel System Fuel Starvation and Hard Start
Fuel Filter: All Technical Service Bulletins Fuel System - Fuel Starvation and Hard Start
Article No. 85-15-19
FUEL STARVATION/HARD START (7.5L) - FUEL SYSTEM SERVICE PROCEDURE
LIGHT TRUCK 1980-85 E & F SERIES
Service procedures for concerns of fuel starvation are summarized as follows. These procedures
apply to motor home and other conversion units with after market pumps and tanks, as well as
vehicles with Ford fuel systems.
1. Vehicles equipped with electric fuel pumps and those converted from mechanical to electric fuel
pumps per TSB's 83-11-12, 83-11-12-S (84-20) and 84-22-14:
Refer to TSB 84-24-14 for a description of the fuel system.
1. Perform service of Fuel System Plumbing Concerns as described on Page 31 of TSB 84-24-14.
NOTE: On motor home vehicles, the fuel tank straps may be ovenightened causing the tank to
collapse, thus blocking the fuel pick-up filter.
2. Check for Fuel System Electrical Concerns as described on Page 37 of the above TSB,
84-24-14.
3. Check for electrical continuity to the fuel pump as described on Page 24-35-8 of the 1985 Light
Truck Shop Manual, Volume B. Then check electric fuel pump operation through Step (d) as
described on the same page of that manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Inertia Switch: > 851519 > Jul > 85 > Fuel System Fuel Starvation and Hard Start > Page 1916
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Inertia Switch: > 851519 > Jul > 85 > Fuel System Fuel Starvation and Hard Start > Page 1917
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Inertia Switch: > 851519 > Jul > 85 > Fuel System Fuel Starvation and Hard Start > Page 1918
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Inertia Switch: > 85610 > Mar > 85 > Fuel Filter Replacement Information
Fuel Filter: All 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Inertia Switch: > 851519 > Jul > 85 > Fuel System Fuel Starvation and Hard Start > Page 1928
Figure 22 - Fuel System
4. Remove and discard the fuel line to the carburetor from the vapor separator, carburetor bronze
fuel filter and gasket. Then rework the fuel system (Figure 22) using the parts listed below.
CAUTION: Back-up wrench must be used on fuel filter during assembly.
Hardware required for fuel system rework: E3TZ-9155-C
Fuel Filter
E5TZ-9C399-A Fuel Line Assembly
D177-9229-A Gasket (Fuel Filter to Carb)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Inertia Switch: > 851519 > Jul > 85 > Fuel System Fuel Starvation and Hard Start > Page 1929
Figure 22 - Fuel System
Figure 23 - Pressure Test Location
5. Pressure test the fuel system as described on Page 24-30-2 of the above Shop Manual. Even
though the test is in the mechanical fuel pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel Pump Inertia Switch: > 851519 > Jul > 85 > Fuel System Fuel Starvation and Hard Start > Page 1930
section, the test procedure is the same for electric fuel pump systems. The pressure should be 3.5
to 4.5 psi. If the pressure is incorrect and a pressure test before the vapor separator as described
below is 5.5 psi. or higher, then replace the vapor separator as shown in Figure
22. However, if the pressure before the vapor separator is low, check the fuel supply line for kinks
and/or blockage. If it is free of kinks and/or blockage, replace the pump/sender assembly. To test
pressure before the vapor separator, install a fuel pressure gauge in fuel line before vapor
separator. This can be done at rubber hose connections downstream from the fuel tank selector
switch, or at the rubber hose connector from the frame to the front of the engine (Figure 23). DO
NOT DISCONNECT FUEL RETURN LINE. Record pressure reading with engine idling. Line
pressure should range from 5.5 to 6.5 psi. between the vapor separator and fuel tank.
If previously tested pressure at the carburetor was below 3.5 psi., install one of the following vapor
separators to increase the fuel pressure.
E3TZ-9N176-A gives 1.0 psi. increase at the carburetor (RED DOT).
E3TZ-9N176-B gives 2.0 psi. increase at the carburetor (BLUE DOT).
If the fuel pressure at the carburetor was too high or the concern still exists, replace the vapor
separator with vapor separator E0TZ-9N176-B. If the pressure is still incorrect, check the fuel
return line for blockage. If the return line is clear, it will be necessary to replace the pump/sender
assembly. After service is completed, recheck pressure at the carburetor to confirm correction of
the concern.
NOTE: Be sure fuel pressure is correct. High fuel pressure may cause carburetor flooding.
II. Vehicles equipped with mechanical fuel pumps:
1. Perform the diagnosis described in the 1985 Light Truck Shop Manual, Volume B, Page 24-30-1.
2. Perform the capacity test and the pressure test described on Page 24-30-2 of the above Shop
Manual.
3. If the fuel starvation condition persists, modify the vehicle as described in TSB's 83-11-12-S
(84-20) and 84-22-14. This applies to vehicles with Ford fuel tanks only. On F Series trucks with
mechanical fuel pump systems, use the 351/400 listing in TSB 83-11-12-S (84-20), but substitute
Kit "G" for Kit "F".
PART NUMBER PART NAME CLASS
E3TZ-9155-C Fuel Filter R
E5TZ-9C399-A Fuel Line Assembly C
D1ZZ-9229-A Gasket C
E3TZ-9N176-A Vapor Separator R
E3TZ-9N176-B Vapor Separator R
E0TZ-9N176-B Vapor Separator A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: "Actual Time" as defined in the
Warranty and Policy Manual. DLR. CODING: Basic Part No. DRIVE - Code: N7, L3, M2, M3, M6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Technical Service Bulletins > Customer Interest: > 83720 > Apr > 83 > Accelerator Linkage Raspy/Sticky
Throttle Cable/Linkage: Customer Interest Accelerator Linkage - Raspy/Sticky
Article No. 83-7-20
ACCELERATOR LINKAGE - DIAGNOSTIC PROCEDURE
LIGHT TRUCKS 1980-83 LIGHT TRUCKS
Servicing of Cable-Type Acceleration Linkage
The following procedure will assist in diagnosing accelerator linkage concerns on 1980-83 light
trucks.
If the accelerator pedal, when operated, is hard to push down or feels "raspy" or "sticky", perform
the following:
1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball
stud. Also disconnect the cruise control from the accelerator cable if so equipped.
2. Then check the following items:
^ Be sure that the disconnected end of the cable or its spring does not come into contact with any
of the surrounding parts.
^ Operate the pedal by foot.
^ If accelerator operation is smooth, the pedal assembly and cable are not the cause of the
concern. Refer to the carburetor/injector pump diagnosis procedures in the appropriate shop
manual for additional checks.
^ E, F, Bronco and Ranger with gas engine - See General Fuel System Service Section 24-01.
^ Ranger with Diesel Engine - See Ranger Shop Manual - 2.2L Diesel Engine Section 22-09 of the
Engine Performance Diagnostic Guide.
^ F Series with the 6.9L Diesel Engine - See the 1983 Car/Truck Shop Manual - Engine Electronics
Section 25-64.
^ If the concern persists (being sure disconnected end of cable has not come into contact with
anything), check foot pedal assembly for free operation. If pedal operation is free, replace the
cable.
If you have a high engine idle speed concern, check the following linkage systems:
1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball
stud. Also disconnect the cruise control from the accelerator cable if so equipped.
^ If the cable ball socket extends beyond the throttle lever ball stud, refer to the carburetor
diagnosis procedures in the appropriate shop manual for the correct adjustment procedure. ^
If the socket does not extend beyond the stud, check the foot pedal assembly for free operation. If
the pedal operation is free, replace the cable.
NOTE: The accelerator cable should not be lubricated and it is not serviceable.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: M TIME:
"Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9A758
Code: 41
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 83720 > Apr > 83 > Accelerator
Linkage - Raspy/Sticky
Throttle Cable/Linkage: All Technical Service Bulletins Accelerator Linkage - Raspy/Sticky
Article No. 83-7-20
ACCELERATOR LINKAGE - DIAGNOSTIC PROCEDURE
LIGHT TRUCKS 1980-83 LIGHT TRUCKS
Servicing of Cable-Type Acceleration Linkage
The following procedure will assist in diagnosing accelerator linkage concerns on 1980-83 light
trucks.
If the accelerator pedal, when operated, is hard to push down or feels "raspy" or "sticky", perform
the following:
1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball
stud. Also disconnect the cruise control from the accelerator cable if so equipped.
2. Then check the following items:
^ Be sure that the disconnected end of the cable or its spring does not come into contact with any
of the surrounding parts.
^ Operate the pedal by foot.
^ If accelerator operation is smooth, the pedal assembly and cable are not the cause of the
concern. Refer to the carburetor/injector pump diagnosis procedures in the appropriate shop
manual for additional checks.
^ E, F, Bronco and Ranger with gas engine - See General Fuel System Service Section 24-01.
^ Ranger with Diesel Engine - See Ranger Shop Manual - 2.2L Diesel Engine Section 22-09 of the
Engine Performance Diagnostic Guide.
^ F Series with the 6.9L Diesel Engine - See the 1983 Car/Truck Shop Manual - Engine Electronics
Section 25-64.
^ If the concern persists (being sure disconnected end of cable has not come into contact with
anything), check foot pedal assembly for free operation. If pedal operation is free, replace the
cable.
If you have a high engine idle speed concern, check the following linkage systems:
1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball
stud. Also disconnect the cruise control from the accelerator cable if so equipped.
^ If the cable ball socket extends beyond the throttle lever ball stud, refer to the carburetor
diagnosis procedures in the appropriate shop manual for the correct adjustment procedure. ^
If the socket does not extend beyond the stud, check the foot pedal assembly for free operation. If
the pedal operation is free, replace the cable.
NOTE: The accelerator cable should not be lubricated and it is not serviceable.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: M TIME:
"Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9A758
Code: 41
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Cable/Linkage: > 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Cable/Linkage: > 841919 >
Sep > 84 > Steering - Pull/Drift Diagnostic Procedures
Tires: All Technical Service Bulletins Steering - Pull/Drift Diagnostic Procedures
Article No. 84-19-19
STEERING PULL/DRIFT/ROADABILITY - DIAGNOSTIC PROCEDURES
LIGHT TRUCKS 1980-84 F100-350, BRONCO, ECONOLINE
Section 19 of the 1983 and 1984 Light Truck Shop Manuals provides procedures to resolve most
roadability concerns experienced to date. These procedures can be applied to any 1980 and later
model light trucks.
When servicing 4 wheel drive vehicles with limited slip front axles, front tire circumference is the
most probable cause if the pull is only present when the hubs are locked. Installing the two most
evenly matched tires on the front axle should resolve the concern.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector >
Component Information > Description and Operation
Ignition Timing Connector: Description and Operation
Fig. 20 Ignition Timing Vacuum Switch
Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition
module to retard spark timing. The switch is closed above the vacuum setting and the ignition
module is in the non-retard spark timing mode. Calibration resistors inside the switch control the
amount of retard.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector >
Component Information > Description and Operation > Page 1974
Ignition Timing Connector: Testing and Inspection
Ignition Timing Vacuum Switch
Ignition Timing Vacuum Switch Test Chart
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less
than'' values in the Ignition Timing vacuum Switch Test chart.
3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured
across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart.
4. Replace switch if resistance is not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators >
System Information > Diagrams
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] >
Component Information > Description and Operation
Ignition Resistor: Description and Operation
The ballast resistor, (wire type), maintains a specific resistance between the positive (Batt.)
terminal of the ignition coil connector and the wiring harness connector. It is not in operation during
engine cranking enabling the coil to receive a hotter signal for starting. Once the engine is running,
the resistor is used to protect the coil from voltage overload.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] >
Component Information > Description and Operation > Page 1981
Ignition Resistor: Testing and Inspection
1. Disconnect module connector with red and white wires then, ignition coil connector.
2. Using a suitable ohmmeter, measure resistance between Batt. terminal of ignition coil connector
and wiring harness connector wire that joins red wire in module connector.
3. If resistance is 0.8---1.6 ohms, ballast resistor is satisfactory. If resistance is less than 0.8 ohms
or greater than 1.6 ohms, replace ballast resistor.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations
Crankshaft Position Sensor: Locations
RH Front Of Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Locations > Page 1985
Crankshaft Position Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit >
Component Information > Specifications
DISTRIBUTOR TIMING ADVANCE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit >
Component Information > Description and Operation > Vacuum Spark Advance Mechanism
Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism
The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly
is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm
assembly used depends on the engine calibration.
Single Diaphragm Assembly
SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the
armature to stator relationship to give spark advance. The stator assembly position is changed by
means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm
assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance
spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached
to the stator assembly, makes the the stator assembly move with respect to the armature. This
changes the initial armature to stator relationship set during initial timing, causing spark advance.
The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly,
is attached to the distributor base.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit >
Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 1992
Dual Diaphragm Assembly
DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in
the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum
advance port causes the advance diaphragm and attached rod to move, otherwise the action is the
same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard
diaphragm to move, compressing the retard spring, which controls the rate of spark retard.
Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by
the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm
rod moves causing the attached stator assembly to change position with respect to the armature. In
this instance the direction of the stator assembly movement is opposite that occurring during
vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port
overrides any spark retard caused by vacuum being applied to the retard port.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit >
Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 1993
Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism
Distributor - Exploded view
The centrifugal advance mechanism varies the relationship of the armature to the stator assembly.
The armature is mounted to the sleeve and plate assembly which rotates in relation to the
distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine
RPM. The movement of the weights change the initial relationship of the armature to the stator
assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor
shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by
calibrated springs.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit >
Component Information > Description and Operation > Page 1994
Distributor Advance Unit: Service and Repair
1. Remove distributor cap and rotor.
2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup
assembly.
3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link.
4. Carefully remove unit from distributor.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Retard Control >
Component Information > Locations
Distributor Retard Control: Locations
Below Vacuum Switch Between No. 5 & No. 6 Spark Plugs
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Vacuum Control >
Component Information > Description and Operation
Distributor Vacuum Control: Description and Operation
3-Port Vacuum Regulator
Vacuum Regulator (3 & 4 Port)
Three port, Fig. 27, regulators and four port, Fig. 28, regulators are used to control the vacuum
advance to the distributor. During engine idle conditions, the manifold vacuum signal is reduced to
a constant output signal. Off idle, the output signal equals the spark port.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Vacuum Control >
Component Information > Testing and Inspection > Distributor Modulator Valve Assembly
Distributor Vacuum Control: Testing and Inspection Distributor Modulator Valve Assembly
1. Turn ignition key to ``ON'' and check resistance at solenoid terminals.
2. If solenoid resistance is not 51---108 ohms, replace solenoid.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Vacuum Control >
Component Information > Testing and Inspection > Distributor Modulator Valve Assembly > Page 2003
Distributor Vacuum Control: Testing and Inspection Vacuum Regulator
Procedure
1. Disconnect vacuum line from distributor port and connect a vacuum gauge.
2. With engine at idle, the vacuum gauge reading should be within 1 inch Hg. vacuum of the
calibration point. The calibration point of each valve can
be identified according to color code as follows: Black, 6 inches Hg.; green, 7 inches Hg.; red, 8
inches Hg.
3. Replace valve if not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Plate W/ Pick-up
Sensor > Component Information > Service and Repair
Distributor Plate W/ Pick-up Sensor: Service and Repair
1. Remove distributor cap and rotor.
2. Remove vacuum advance unit and magnetic pickup assembly.
3. Remove attaching screws and lift base plate from distributor.
4. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Vacuum Spark Delay Valve >
Component Information > Description and Operation
Vacuum Spark Delay Valve: Description and Operation
Fig.25 - Spark Delay Valve
This unit is used in conjunction with some of the other Ford systems. Its purpose is to further
reduce emissions by delaying the spark advance during rapid acceleration and by cutting off
advance immediately upon deceleration. Fig. 25.
This plastic disc-shaped valve is installed in the carburetor vacuum line at the distributor advance
diaphragm. It is a one way valve and will not operate if installed backwards. The black side of the
valve must be toward the carburetor. This valve cannot be repaired.
NOTE: On all systems which employ the dual diaphragm distributor the line which has high vacuum
at idle (normal operating temperature) is
connected to the secondary (retard) side of the distributor vacuum advance unit. This is the
connection closest to the distributor cap.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Vacuum Spark Delay Valve >
Component Information > Description and Operation > Page 2010
Vacuum Spark Delay Valve: Testing and Inspection
Fig.36 - SDV Valve Color Coding
Fig.37 - Spark Delay Valve (SDV) Specifications Chart
Refer to Figs. 36 & 37 for number value by color code.
NOTE: To perform the following procedure, an external vacuum source capable of maintaining a
minimum constant 10 inches Hg. is required.
Mono Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect black side of delay valve to vacuum
source.
2. Connect a vacuum gauge with a 24 inch hose to colored side of delay valve.
3. Apply 10 inches Hg. vacuum and observe time in seconds for gauge to read 0-8 inches Hg. The
minimum and maximum time for gauge to read 8
inches Hg. should be as shown in Fig. 37.
Dual Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect vacuum gauge with a 24 inch hose to
DIST nipple of delay valve.
2. Connect black side of delay valve and CARB nipple of delay valve to vacuum source.
NOTE: Avoid applying vacuum to CARB nipple while applying vacuum to black side of valve.
3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches
Hg. The minimum and maximum time for gauge to
read 8 inches Hg. should be as shown in Fig. 37.
Retard Delay Valve
1. Set external vacuum source to 10 inches Hg. and connect colored side of delay valve to vacuum
source.
2. Connect a vacuum gauge with a 24 inch hose to white side of delay valve.
3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches
Hg. The minimum and maximum time for gauge to
read 8 inches Hg. should be as shown in Fig. 37.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing
and Inspection
Ignition Cable: Testing and Inspection
Spark Plug Wire Resistance
*** UPDATED BY TSB #85-9-33
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Ignition - Coil Durability/Radio Frequency Interference
Ignition Coil: Technical Service Bulletins Ignition - Coil Durability/Radio Frequency Interference
Article No. 84-22-8
IGNITION - COIL DURABILITY AND RADIO FREQUENCY INTERFERENCE
LIGHT TRUCKS 1985 AND PRIOR YEARS - ALL SERIES
MEDIUM/HEAVY TRUCKS 1985 AND PRIOR YEARS - ALL SERIES
Relocation of the ignition coil to accomodate the installation of non-Ford engine-mounted
equipment may effect the durability of the coil and/or cause a radio frequency interference
condition. For these reasons movement of the ignition coil from its original location is not
recommended.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Page 2018
Ignition Coil: Specifications
Winding Resistance (ohms at 75 degrees F or 24 degrees C) 1981: Primary, 0-1; Secondary,
7700-9600. 1982-88 w/Dura-Spark; Primary, 0.8-1.6; Secondary, 7700-10,500. 1984-88 w/TFI
(EEC IV): Primary, 0.3-1.0; Secondary, 8000-11,500.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Page 2019
Ignition Coil: Locations
LH Side Of V8-460/7.
Top Of 8 Cyl, LH Side Of 6 Cyl Engine
Applicable to: 5L Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Page 2020
Ignition Coil: Testing and Inspection
1. Disconnect ignition coil electrical connector.
2. Using a suitable ohmmeter, measure resistance between coil Batt. terminal and Tach terminal.
3. If reading obtained is 0.8---1.6 ohms, coil is satisfactory. If not, replace coil.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Description and Operation
Ignition Control Module: Description and Operation
Typical Ignition System
The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic
pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short
period of time. High voltage is created each time the magnetic field is built up and collapsed. The
red ignition module wire provides operating voltage for the module's electronic components in the
Run mode. The white module wire and start bypass provide increased voltage for the module and
coil during Start mode.
Ignition Modules
Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control
signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the
Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this
second signal, the UIM provides additional spark timing control for certain operating conditions by
shutting off the ignition coil current flow at a different time than with just the distributor pick-up
signal.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Description and Operation > Page 2024
Module Identification Chart
For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura
Spark II has 6 wire connector while Dura Spark III has a 5 wire connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component
Information > Description and Operation
Ignition Timing Connector: Description and Operation
Fig. 20 Ignition Timing Vacuum Switch
Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition
module to retard spark timing. The switch is closed above the vacuum setting and the ignition
module is in the non-retard spark timing mode. Calibration resistors inside the switch control the
amount of retard.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component
Information > Description and Operation > Page 2028
Ignition Timing Connector: Testing and Inspection
Ignition Timing Vacuum Switch
Ignition Timing Vacuum Switch Test Chart
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less
than'' values in the Ignition Timing vacuum Switch Test chart.
3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured
across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart.
4. Replace switch if resistance is not within specifications.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Description and Operation
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Description and Operation > Page 2032
Knock Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information >
Specifications > Electrical Specifications
DISTRIBUTOR PICKUP
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information >
Specifications > Electrical Specifications > Page 2037
DISTRIBUTOR PICKUP
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information >
Specifications > Page 2038
Pick-Up Coil: Testing and Inspection
Procedure
1. Disconnect distributor electrical connector. Inspect connections for dirt or corrosion. 2. Using a
suitable ohmmeter, measure resistance across orange and purple wires in distributor connector. 3.
If readings obtained are within 400---1000 ohms, circuit is satisfactory. If readings are less than 400
or more than 1000 ohms, replace stator
assembly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Description and Operation
Ignition Control Module: Description and Operation
Typical Ignition System
The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic
pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short
period of time. High voltage is created each time the magnetic field is built up and collapsed. The
red ignition module wire provides operating voltage for the module's electronic components in the
Run mode. The white module wire and start bypass provide increased voltage for the module and
coil during Start mode.
Ignition Modules
Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control
signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the
Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this
second signal, the UIM provides additional spark timing control for certain operating conditions by
shutting off the ignition coil current flow at a different time than with just the distributor pick-up
signal.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Description and Operation > Page 2043
Module Identification Chart
For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura
Spark II has 6 wire connector while Dura Spark III has a 5 wire connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
RH Front Of Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Locations > Page 2048
Crankshaft Position Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Component Information > Service and Repair
Ignition Switch: Service and Repair
Fig. 3 Ignition switch replacement
1. Disconnect battery ground cable.
2. Remove steering column shroud and lower the steering column.
3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts.
4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Description and Operation
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Description and Operation > Page 2055
Knock Sensor: Testing and Inspection
Ford provides trouble code/symptom driven diagnostics for this component. For complete diagnosis
and pinpoint testing, refer to Computers and Control Systems, Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications
Spark Plug: Specifications
Spark Plugs 5-10 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Vacuum Switch <--> [Thermal
Vacuum Valve, Vacuum/Dist. Advance] > Component Information > Description and Operation
Ignition Timing Vacuum Switch: Description and Operation
This system used on some vehicles, consists of an ambient temperature switch, a three-way
vacuum valve, a latching relay and an external inline vacuum bleed. The three-way vacuum valve
is used to select the carburetor vacuum source that is supplied to the distributor vacuum advance
mechanism. The ambient temperature switch provides the switching circuit to determine which
vacuum source will be selected as a function of outside air temperature. The latching relay,
activated by temperature switch closing, remains energized regardless of temperature switch
position which prevents system cycling due to minor ambient temperature changes. The inline
vacuum bleed function is to purge the vacuum line in the CTAV system of any excessive gasoline
vapors.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Ignition System > Vacuum Restrictor > Component Information >
Description and Operation
Vacuum Restrictor: Description and Operation
Fig.30 - Vacuum Restrictor
The orifice type flow restrictor, Fig. 30, is used on some systems to control the flow rate and or
timing characteristics to the following systems:
a. EGR valve timing (opening and closing).
b. Part throttle spark advance.
c. Purge system.
d. Thermactor system
The flow rate through the restrictor is the same in both directions. If blocked, it should be replaced.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > System Information > System
Diagnosis
Transmission Control Systems: Testing and Inspection
For Transmission Control Systems Diagnosis, go to Powertrain Management/Computers and
Control Systems/Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > A L L Diagnostic Trouble Codes - Trans and Drivetrain > System
Information > System Diagnosis
A L L Diagnostic Trouble Codes - Trans and Drivetrain: Testing and Inspection
For Transmission related codes, proceed to Computers and Control Systems.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Technical Service Bulletins > A/T - AOD New Overdrive Band Anchor Pin
Band: Technical Service Bulletins A/T - AOD New Overdrive Band Anchor Pin
Article No. TRANSMISSION - AUTOMATIC OVERDRIVE
87-22-13 (AOD) - NEW OVERDRIVE BAND ANCHOR PIN - VEHICLES BUILT BEFORE 09/30/86
FORD: 1980-87 MUSTANG, THUNDERBIRD, FORD
LINCOLN-MERCURY: 1980-83 MARK VI 1980-87 COUGAR, MERCURY, CONTINENTAL,
LINCOLN TOWN CAR
LIGHT TRUCK: 1980-87 E SERIES, F SERIES, BRONCO
ISSUE: A new overdrive band anchor pin, with a stepped diameter, is available for service. The old
pin may have caused overdrive band wear or anchor pin leakage on vehicles built before 09/30/86.
NOTE: AOD transmissions built after 09/30/86 have the new design overdrive band anchor pin.
This pin is NOT serviceable on transmissions built after 09/30/86. If replacement is required, a new
transmission case must be installed.
Figure 10
ACTION: If service is required, use the appropriate Car or Light Truck Shop Manual, Section 17-20,
for installation of the new overdrive band anchor pin, Figure 10.
PART NUMBER PART NAME CLASS
E2AZ-7F295-A Anchor Pin C
E0AZ-19554-BA Ford Stud and B
Bearing Mount
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Adjustments > C5 Transmission
Band: Adjustments C5 Transmission
Intermediate Band
Intermediate Band Adjustment
1. Clean all the dirt from the band adjusting screw area. Remove and discard the locknut
2. Install a new locknut on the adjustment screw.
3. Tighten the adjusting screw using Band Adjusting Ratchet T71 P-77370-H and Socket T71
P-77370-D or equivalent. Tool T71 P-77370-H or
equivalent, is a pre-set torque wrench which will click when the torque on the adjusting screw
reaches 13.5 Nm (10 lb-ft).
4. Back off the adjusting screw exactly 4 1/4 turns.
5. Hold the adjusting screw from turning and tighten the locknut to 54 Nm (40 lb-ft).
Low/Reverse Band
Low Reverse Band Adjustment
1. Clean all the dirt from the band adjusting screw area. Remove and discard the locknut.
2. Install a new locknut on the adjusting screw.
3. Tighten the adjusting screw using Band Adjusting Ratchet T71 P-77370-H and Socket T71
P-77370-D or equivalent. Tool T71 P-77370-H or
equivalent, is a pre-set torque wrench which will click when the torque on the adjusting screw
reaches 13.5 Nm (10 lb-ft).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Adjustments > C5 Transmission > Page 2079
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Adjustments > C5 Transmission > Page 2080
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Clutch: > 831310 > Jun > 83 > A/T - No 3rd to 4th Gear
Upshift or Slipping 4th Gear
Clutch: Customer Interest A/T - No 3rd to 4th Gear Upshift or Slipping 4th Gear
Article No. 83-13-10
TRANSMISSION - AUTOMATIC - AOD NO 3-4 UPSHIFT OR SLIPPING 4TH GEAR
FORD
1980-83 FORD, THUNDERBIRD, LTD
LINCOLN-MERCURY 1980-83 MERCURY, COUGAR, LINCOLN, MARK, CONTINENTAL,
MARQUIS
LIGHT TRUCKS 1981-83 F-SERIES AND E-SERIES
Customer concerns of a no 3-4 upshift or a slipping 4th gear can result from causes such as: the
direct clutch check ball leaking, miscellaneous leakage or a blocked hydraulic circuit condition,
improper torque on the valve body or sticking valves, a leaking governor, the converter damper/hub
assembly malfunctioning.
Replacement of the direct clutch cylinder piston assembly to alleviate check ball leakage has been
effective in most instances.
To verify the direct clutch circuit leakage concern, perform the pressure test below as stated
previously. Leakage in the direct clutch circuit has been attributed most of the time to a leaking
check ball in the direct clutch piston. Replacement of the direct clutch piston will alleviate this
condition. However, since other factors can be involved, the following additional
checks/verifications are listed to aid you in a complete comprehensive concern diagnosis for
customer symptoms of a no 3-4 shift or a slipping 4th gear.
NOTE: To alleviate the direct clutch check ball wedging concern in the piston, a star washer
replaced the staking operation mid-March, 1983. All current service parts depot stock have the
updated direct clutch piston level.
Preliminary Checks/Information Verify the following steps have been accomplished:
^ Road test the vehicle to verify the customer complaint. A no 3-4 upshift is characterized by
staying in 3rd gear. A slipping 4th gear is characterized by engine cut-loose on the 3-4 upshift and
no 4th gear drive capability.
^ Check TV rod and see if bent or sticking.
^ Check TV linkage (could be misadjusted long).
Bent, sticking or misadjusted TV linkage will not properly synchronize with the carburetor lever at
the time a 3-4 shift should occur.
^ Check control pressure and throttle pressure to identify that they are within specifications.
The new 3-4 shift valve (refer to TSB 83-10-11) changes the 3-4 shift pattern. The shift will occur at
a higher mph.
Direct Clutch Pressure Test
The direct clutch pressure test outlined below will diagnose a low pressure condition or leakage in
the direct clutch circuit. A difference of 15 psi or more between direct clutch pressure and line
pressure (read at the forward clutch pressure tap) will prevent a 3-4 shift.
1. Attach 0-300 psi pressure gages to the forward clutch pressure tap and to the direct clutch
pressure tap. Gage accuracy must be capable of distinguishing a 15 psi difference. (If this test is
done in conjunction with a control pressure test, pressure gages will be attached to all pressure
taps.) Have sufficient flexible hose to read the gages in the vehicle.
CAUTION: PRESSURE GAGES AFFECT THE SHIFT QUALITY OF THE TRANSMISSION. CARE
SHOULD BE TAKEN NOT TO
ACCELERATE OR DECELERATE RAPIDLY. POSSIBLE TRANSMISSION FAILURE COULD
RESULT.
2. Drive the vehicle. When pressure is applied to the direct clutch, note the difference between the
line pressure read at forward clutch pressure tap and the direct clutch pressure.
3. If the difference in pressures is less than 15 psi, the direct clutch circuit is OK.
4. If the difference is greater than 15 psi, there could be a leak in the direct clutch pressure circuit.
(Proceed to the No 3-4 Upshift With Direct Clutch Pressure Greater Than 15 PSI Diagnostic
Procedure). If the difference does exceed 15 psi, the gages on line pressure and direct clutch
pressure can be switched to confirm that gage calibration difference is not the cause. (Proceed to
the No 3-4 Upshift With Direct Clutch Pressure Less Than 15 PSI Diagnostic Procedure or to the
Slipping 4th Gear Diagnostic Procedure if applicable).
No 3-4 Upshift With Direct Clutch Pressure Greater Than 15 PSI (Indicates Linkage) Diagnostic
Procedure
NOTE: Direct clutch plates burnt will help to confirm leakage in the direct clutch circuit. Replacing
only the plates and not finding the cause could
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > Customer Interest for Clutch: > 831310 > Jun > 83 > A/T - No 3rd to 4th Gear
Upshift or Slipping 4th Gear > Page 2089
result in a repeat service.
^ Check torque on valve body bolts.
^ Check to see if main control gasket is blocking an orifice.
^ Check for nicks or porosity in the case passages (valve body to case mating surface).
^ Check the direct clutch piston check ball for leakage
- inspect the piston check ball for freedom of movement. Improper seating of check ball will cause
leakage. Leakage can be detected by turning the piston upside down (flat side of piston facing you)
allowing the check ball to seat in the piston. Pour a small quantity of solvent over the check ball. If
solvent drops past the check ball, replace the piston.
^ Inspect the output shaft feed passages and the cup plug for leakage. Apply 5-10 psi air to the
output shaft feed passages. Refer to the AOD operation and diagnosis guide (course 1720-001) p.
32 for location of the feed passages. If air comes out the wrong feed passage, replace the output
shaft.
^ Check direct clutch piston seal rings (inner and outer) for leakage.
^ Check all direct clutch output shaft seals for freedom of movement and for metal shavings and
burrs between seal and output shaft.
^ Check the direct clutch cylinder for groove marks on the rear ID of the drum. Groove marks
indicate the small cast iron seal rings are turning with the output shaft and grooving the cylinder.
Groove marks may be caused by contamination or burrs in the output
shaft ring groove causing the seal rings to turn with the output shaft. Visually check the output ring
grooves carefully. Replace as necessary the output shaft, the seal rings and the cylinder.
No 3-4 Upshift With Direct Clutch Pressure Less Than 15 PSI (Indicates No Leakage In The Direct
Clutch Circuit) Diagnostic Procedure
^ Clean the valve body. Check for sticking valves as follows: Overdrive servo regulator valve; 3-4
shift valve; 3-4 TV modulator valve; orifice control valve. If any valves are sticking and they cannot
be freed, replace valve body.
^ Reduce valve body bolt torque to minimum side of specification 80 in.lbs.
^ Check the fit of the governor counterweight on the output shaft. If the fit is sloppy, replace the
counterweight.
^ Check the governor to output shaft retaining ring to make sure it is properly seated on the output
shaft. Service as necessary.
^ Check last two large seal rings on the output shaft (#9, #10). They should move freely. Check for
metal shaving contamination or burrs between the seal and output shaft. Replace as necessary.
^ Check the seal ring bore at the rear of case for scoring. Light scoring is permissable. Deep
grooving indicates case wear. Replace case for deep grooving.
Slipping 4th Gear Diagnostic Procedure
NOTE: Burnt overdrive band will help confirm leakage in the overdrive circuit. Replacing only the
overdrive band without finding the cause will result in a repeat service. If the overdrive band is not
burnt, the converter damper/hub weld has usually been found to be suspect.
^ Check overdrive servo cover O-rings and servo piston seal for possible leakage. Replace O-rings
and seal if leakage is evident.
^ Verify the overdrive servo cover is not cracked/porous. Coat cover with fluid. Apply air to
overdrive servo, apply passage using tool (T80L- 77030-B). Observe to see if air bubbles are
present on overdrive servo cover. Replace cover if air bubbles are present.
^ Check the overdrive servo case apply passage to see if it is blocked. Air pressure test. Replace
case if necessary.
^ Verify the overdrive servo piston is seated correctly to the band end seat.
^ Verify the overdrive band is seated correctly to anchor pin.
^ Check the torque converter for damper/hub weld
failure. Perform converter damper/hub assembly weld check procedure. Refer to Shop Manual,
Section 17-01. Use special service tools T83L-7902- A.
Replace converter if shaft turns more than two degrees or if there is a grinding noise while applying
50 ft.lbs. torque.
^ Check splines on both ends of the direct driveshaft and in direct clutch cylinder for distortion.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 831310 > Jun > 83 > A/T - No 3rd to
4th Gear Upshift or Slipping 4th Gear
Clutch: All Technical Service Bulletins A/T - No 3rd to 4th Gear Upshift or Slipping 4th Gear
Article No. 83-13-10
TRANSMISSION - AUTOMATIC - AOD NO 3-4 UPSHIFT OR SLIPPING 4TH GEAR
FORD
1980-83 FORD, THUNDERBIRD, LTD
LINCOLN-MERCURY 1980-83 MERCURY, COUGAR, LINCOLN, MARK, CONTINENTAL,
MARQUIS
LIGHT TRUCKS 1981-83 F-SERIES AND E-SERIES
Customer concerns of a no 3-4 upshift or a slipping 4th gear can result from causes such as: the
direct clutch check ball leaking, miscellaneous leakage or a blocked hydraulic circuit condition,
improper torque on the valve body or sticking valves, a leaking governor, the converter damper/hub
assembly malfunctioning.
Replacement of the direct clutch cylinder piston assembly to alleviate check ball leakage has been
effective in most instances.
To verify the direct clutch circuit leakage concern, perform the pressure test below as stated
previously. Leakage in the direct clutch circuit has been attributed most of the time to a leaking
check ball in the direct clutch piston. Replacement of the direct clutch piston will alleviate this
condition. However, since other factors can be involved, the following additional
checks/verifications are listed to aid you in a complete comprehensive concern diagnosis for
customer symptoms of a no 3-4 shift or a slipping 4th gear.
NOTE: To alleviate the direct clutch check ball wedging concern in the piston, a star washer
replaced the staking operation mid-March, 1983. All current service parts depot stock have the
updated direct clutch piston level.
Preliminary Checks/Information Verify the following steps have been accomplished:
^ Road test the vehicle to verify the customer complaint. A no 3-4 upshift is characterized by
staying in 3rd gear. A slipping 4th gear is characterized by engine cut-loose on the 3-4 upshift and
no 4th gear drive capability.
^ Check TV rod and see if bent or sticking.
^ Check TV linkage (could be misadjusted long).
Bent, sticking or misadjusted TV linkage will not properly synchronize with the carburetor lever at
the time a 3-4 shift should occur.
^ Check control pressure and throttle pressure to identify that they are within specifications.
The new 3-4 shift valve (refer to TSB 83-10-11) changes the 3-4 shift pattern. The shift will occur at
a higher mph.
Direct Clutch Pressure Test
The direct clutch pressure test outlined below will diagnose a low pressure condition or leakage in
the direct clutch circuit. A difference of 15 psi or more between direct clutch pressure and line
pressure (read at the forward clutch pressure tap) will prevent a 3-4 shift.
1. Attach 0-300 psi pressure gages to the forward clutch pressure tap and to the direct clutch
pressure tap. Gage accuracy must be capable of distinguishing a 15 psi difference. (If this test is
done in conjunction with a control pressure test, pressure gages will be attached to all pressure
taps.) Have sufficient flexible hose to read the gages in the vehicle.
CAUTION: PRESSURE GAGES AFFECT THE SHIFT QUALITY OF THE TRANSMISSION. CARE
SHOULD BE TAKEN NOT TO
ACCELERATE OR DECELERATE RAPIDLY. POSSIBLE TRANSMISSION FAILURE COULD
RESULT.
2. Drive the vehicle. When pressure is applied to the direct clutch, note the difference between the
line pressure read at forward clutch pressure tap and the direct clutch pressure.
3. If the difference in pressures is less than 15 psi, the direct clutch circuit is OK.
4. If the difference is greater than 15 psi, there could be a leak in the direct clutch pressure circuit.
(Proceed to the No 3-4 Upshift With Direct Clutch Pressure Greater Than 15 PSI Diagnostic
Procedure). If the difference does exceed 15 psi, the gages on line pressure and direct clutch
pressure can be switched to confirm that gage calibration difference is not the cause. (Proceed to
the No 3-4 Upshift With Direct Clutch Pressure Less Than 15 PSI Diagnostic Procedure or to the
Slipping 4th Gear Diagnostic Procedure if applicable).
No 3-4 Upshift With Direct Clutch Pressure Greater Than 15 PSI (Indicates Linkage) Diagnostic
Procedure
NOTE: Direct clutch plates burnt will help to confirm leakage in the direct clutch circuit. Replacing
only the plates and not finding the cause could
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 831310 > Jun > 83 > A/T - No 3rd to
4th Gear Upshift or Slipping 4th Gear > Page 2095
result in a repeat service.
^ Check torque on valve body bolts.
^ Check to see if main control gasket is blocking an orifice.
^ Check for nicks or porosity in the case passages (valve body to case mating surface).
^ Check the direct clutch piston check ball for leakage
- inspect the piston check ball for freedom of movement. Improper seating of check ball will cause
leakage. Leakage can be detected by turning the piston upside down (flat side of piston facing you)
allowing the check ball to seat in the piston. Pour a small quantity of solvent over the check ball. If
solvent drops past the check ball, replace the piston.
^ Inspect the output shaft feed passages and the cup plug for leakage. Apply 5-10 psi air to the
output shaft feed passages. Refer to the AOD operation and diagnosis guide (course 1720-001) p.
32 for location of the feed passages. If air comes out the wrong feed passage, replace the output
shaft.
^ Check direct clutch piston seal rings (inner and outer) for leakage.
^ Check all direct clutch output shaft seals for freedom of movement and for metal shavings and
burrs between seal and output shaft.
^ Check the direct clutch cylinder for groove marks on the rear ID of the drum. Groove marks
indicate the small cast iron seal rings are turning with the output shaft and grooving the cylinder.
Groove marks may be caused by contamination or burrs in the output
shaft ring groove causing the seal rings to turn with the output shaft. Visually check the output ring
grooves carefully. Replace as necessary the output shaft, the seal rings and the cylinder.
No 3-4 Upshift With Direct Clutch Pressure Less Than 15 PSI (Indicates No Leakage In The Direct
Clutch Circuit) Diagnostic Procedure
^ Clean the valve body. Check for sticking valves as follows: Overdrive servo regulator valve; 3-4
shift valve; 3-4 TV modulator valve; orifice control valve. If any valves are sticking and they cannot
be freed, replace valve body.
^ Reduce valve body bolt torque to minimum side of specification 80 in.lbs.
^ Check the fit of the governor counterweight on the output shaft. If the fit is sloppy, replace the
counterweight.
^ Check the governor to output shaft retaining ring to make sure it is properly seated on the output
shaft. Service as necessary.
^ Check last two large seal rings on the output shaft (#9, #10). They should move freely. Check for
metal shaving contamination or burrs between the seal and output shaft. Replace as necessary.
^ Check the seal ring bore at the rear of case for scoring. Light scoring is permissable. Deep
grooving indicates case wear. Replace case for deep grooving.
Slipping 4th Gear Diagnostic Procedure
NOTE: Burnt overdrive band will help confirm leakage in the overdrive circuit. Replacing only the
overdrive band without finding the cause will result in a repeat service. If the overdrive band is not
burnt, the converter damper/hub weld has usually been found to be suspect.
^ Check overdrive servo cover O-rings and servo piston seal for possible leakage. Replace O-rings
and seal if leakage is evident.
^ Verify the overdrive servo cover is not cracked/porous. Coat cover with fluid. Apply air to
overdrive servo, apply passage using tool (T80L- 77030-B). Observe to see if air bubbles are
present on overdrive servo cover. Replace cover if air bubbles are present.
^ Check the overdrive servo case apply passage to see if it is blocked. Air pressure test. Replace
case if necessary.
^ Verify the overdrive servo piston is seated correctly to the band end seat.
^ Verify the overdrive band is seated correctly to anchor pin.
^ Check the torque converter for damper/hub weld
failure. Perform converter damper/hub assembly weld check procedure. Refer to Shop Manual,
Section 17-01. Use special service tools T83L-7902- A.
Replace converter if shaft turns more than two degrees or if there is a grinding noise while applying
50 ft.lbs. torque.
^ Check splines on both ends of the direct driveshaft and in direct clutch cylinder for distortion.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T Mercon V ATF Usage
Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage
TSB 06-14-4
07/24/06
MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID.
FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993
Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996
Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996
Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004
Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650,
F-750
LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator
2002-2003 Blackwood
MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer
1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner
MERKUR: 1985-1989 XR4TI
This article supersedes TSB 01-15-7 to update the vehicle application chart.
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid.
ACTION Beginning immediately all automatic transmission / transaxle applications requiring
MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission
Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R)
Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will
only continue for however long it takes to deplete what remains in inventory.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T Mercon V ATF Usage > Page 2104
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T Mercon V ATF Usage > Page 2105
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid
Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid
TRANSMISSION - AUTOMATIC/MANUAL - Article No.
NEW FLUID AND USAGE CHART 87-18-14
FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS,
THUNDERBIRD, FORD
LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior
TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II,
AEROSTAR
ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart),
(XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON"
transmission fluid, where specified, will improve cold weather shift effort and synchronized
operation.
ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic
transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles.
NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual
transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the
transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent.
PART NUMBER PART NAME CLASS
XT-2-QDX MERCON - Quart V
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid > Page 2110
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 861117 > Jun > 86 > A/T Synthetic Fluid Availability
Fluid - A/T: All Technical Service Bulletins A/T - Synthetic Fluid Availability
Article No. 86-11-17
TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC
TRANSMISSION FLUID
FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986
TAURUS
LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR,
CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE
LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER
A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part
number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a
wider range of temperatures.
In the event a vehicle will be operated in extremely cold temperatures for an extended period of
time, remove all existing fluid from the transmission (using the procedure shown in the applicable
1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid,
E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer
weather.
CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid.
PART NUMBER PART NAME CLASS
E6AZ-19582-B Synthetic Dexron Oil V
Automatic Transmission Oil
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 861117 > Jun > 86 > A/T - Synthetic Fluid Availability
Fluid - A/T: Customer Interest A/T - Synthetic Fluid Availability
Article No. 86-11-17
TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC
TRANSMISSION FLUID
FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986
TAURUS
LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR,
CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE
LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER
A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part
number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a
wider range of temperatures.
In the event a vehicle will be operated in extremely cold temperatures for an extended period of
time, remove all existing fluid from the transmission (using the procedure shown in the applicable
1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid,
E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer
weather.
CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid.
PART NUMBER PART NAME CLASS
E6AZ-19582-B Synthetic Dexron Oil V
Automatic Transmission Oil
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V
ATF Usage
Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage
TSB 06-14-4
07/24/06
MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID.
FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993
Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996
Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996
Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004
Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650,
F-750
LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator
2002-2003 Blackwood
MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer
1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner
MERKUR: 1985-1989 XR4TI
This article supersedes TSB 01-15-7 to update the vehicle application chart.
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid.
ACTION Beginning immediately all automatic transmission / transaxle applications requiring
MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission
Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R)
Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will
only continue for however long it takes to deplete what remains in inventory.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V
ATF Usage > Page 2125
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V
ATF Usage > Page 2126
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid
Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid
TRANSMISSION - AUTOMATIC/MANUAL - Article No.
NEW FLUID AND USAGE CHART 87-18-14
FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS,
THUNDERBIRD, FORD
LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior
TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II,
AEROSTAR
ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart),
(XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON"
transmission fluid, where specified, will improve cold weather shift effort and synchronized
operation.
ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic
transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles.
NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual
transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the
transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent.
PART NUMBER PART NAME CLASS
XT-2-QDX MERCON - Quart V
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid > Page 2131
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Refill Capacity
Fluid - A/T: Specifications
Type MERCON(R) Automatic Transmission Fluid
CAPACITY, Initial Refill*: C-6 5.0 qt (US)
With the engine at operating temperature, shift
transmission through all gears. Check fluid level in PARK
and add fluid as needed
Others 3.0 qt (US)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Refill Capacity > Page 2134
Fluid - A/T: Specifications
Type MA(MERCON (R) Automatic Transmission Fluid)
CAPACITY, Total Fill: Tempo, Topaz 8.3 qt (US)
Others 9.8 qt (US)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 85247 > Dec > 85 > A/T - AOD
Fluid Leak
Fluid Pump: Customer Interest A/T - AOD Fluid Leak
Article No. 85-24-7
LEAK - TRANSMISSION FLUID (AOD) - FRONT PUMP SEAL
FORD 1980-85 FORD, THUNDERBIRD, LTD, MUSTANG
LINCOLN-MERCURY 1980-85 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, MARK,
CONTINENTAL
LIGHT TRUCK 1982-85 E AND F SERIES, BRONCO
Figure 12 - Front Pump Seal
Transmission fluid leaks at the front pump seal in vehicles equipped with an AOD transmission built
prior to October 1, 1985 may be caused by a variation in location of the fluid drainback hole at the
pump allowing fluid to leak around the seal. If the drainback hole bridges across the outer edge of
the pump seal, the seal may collapse in the hole causing a leak past the outside diameter of the
seal (Figure 12).
1. Remove the front pump seal using procedures outlined in Section l7-20-34 of the 1985 Car Shop
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 85247 > Dec > 85 > A/T - AOD
Fluid Leak > Page 2143
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 85247 > Dec > 85 > A/T - AOD
Fluid Leak > Page 2144
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 85247 > Dec > 85
> A/T - AOD Fluid Leak
Fluid Pump: All Technical Service Bulletins A/T - AOD Fluid Leak
Article No. 85-24-7
LEAK - TRANSMISSION FLUID (AOD) - FRONT PUMP SEAL
FORD 1980-85 FORD, THUNDERBIRD, LTD, MUSTANG
LINCOLN-MERCURY 1980-85 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, MARK,
CONTINENTAL
LIGHT TRUCK 1982-85 E AND F SERIES, BRONCO
Figure 12 - Front Pump Seal
Transmission fluid leaks at the front pump seal in vehicles equipped with an AOD transmission built
prior to October 1, 1985 may be caused by a variation in location of the fluid drainback hole at the
pump allowing fluid to leak around the seal. If the drainback hole bridges across the outer edge of
the pump seal, the seal may collapse in the hole causing a leak past the outside diameter of the
seal (Figure 12).
1. Remove the front pump seal using procedures outlined in Section l7-20-34 of the 1985 Car Shop
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 85247 > Dec > 85
> A/T - AOD Fluid Leak > Page 2150
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 85247 > Dec > 85
> A/T - AOD Fluid Leak > Page 2151
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > A/T - AOD Main Control Valve Body Gasket
Seals and Gaskets: Technical Service Bulletins A/T - AOD Main Control Valve Body Gasket
Article No. 86-13-17
TRANSMISSION - AUTOMATIC - AOD - MAIN CONTROL VALVE BODY GASKETS
FORD 1980-86 FORD, THUNDERBIRD, LTD, MUSTANG
LINCOLN-MERCURY 1980-83 MARK VI; 1980-86 MERCURY, COUGAR, MARQUIS, CAPRI,
LINCOLN, CONTINENTAL; 1984-86 MARK VII
LIGHT TRUCK 1981-86 E SERIES, F SERIES, BRONCO
Figure 11
Figure 12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > A/T - AOD Main Control Valve Body Gasket > Page 2156
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Component Information > Technical Service Bulletins > Recalls: > NHTSA82V004000 > Jan > 82 > Recall 82V004000: Shift
Rod Attachment
Shift Linkage: Recalls Recall 82V004000: Shift Rod Attachment
ON SOME OF THE INVOLVED VEHICLES, THE SHIFT ROD IN THE TRANSMISSION MAY NOT
BE PROPERLY SEATED IN THE RETENTION GROMMET OF THE STEERING COLUMN SHIFT
LEVER ASSEMBLY. IF THE SHIFT ROD WERE TO DISENGAGE, THE DRIVER COULD NOT
SELECT THE PROPER TRANSMISSION FUNCTION WHICH WOULD CREATE THE
POTENTIAL FOR UNEXPECTED MOVEMENT OF THE VEHICLE. DEALER WILL INSPECT THE
SHIFT ROD ATTACHMENT AND MAKE SURE IT IS PROPERLY SEATED AT NO COST TO
OWNER.
VEHICLE DESCRIPTION: TRUCKS EQUIPPED WITH AUTOMATIC TRANSMISSIONS.
SYSTEM: POWER TRAIN; TRANSMISSION SHIFT LINKAGE. CONSEQUENCES OF DEFECT:
SHOULD SEPARATION OCCUR WHILE VEHICLE IS IN OPERATION, LOSS OF VEHICLE
CONTROL, AN ACCIDENT, AND PERSONAL INJURY COULD OCCUR.
NOTE: THE DRIVER IS ADVISED NOT TO OPERATE VEHICLE UNTIL PROPER
ADJUSTMENTS HAVE BEEN MADE.
1982 FORD TRUCK CLUB WAGON 1982 FORD TRUCK E100 1982 FORD TRUCK E150 1982
FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK ECONOLINE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA82V004000 > Jan > 82 >
Recall 82V004000: Shift Rod Attachment
Shift Linkage: All Technical Service Bulletins Recall 82V004000: Shift Rod Attachment
ON SOME OF THE INVOLVED VEHICLES, THE SHIFT ROD IN THE TRANSMISSION MAY NOT
BE PROPERLY SEATED IN THE RETENTION GROMMET OF THE STEERING COLUMN SHIFT
LEVER ASSEMBLY. IF THE SHIFT ROD WERE TO DISENGAGE, THE DRIVER COULD NOT
SELECT THE PROPER TRANSMISSION FUNCTION WHICH WOULD CREATE THE
POTENTIAL FOR UNEXPECTED MOVEMENT OF THE VEHICLE. DEALER WILL INSPECT THE
SHIFT ROD ATTACHMENT AND MAKE SURE IT IS PROPERLY SEATED AT NO COST TO
OWNER.
VEHICLE DESCRIPTION: TRUCKS EQUIPPED WITH AUTOMATIC TRANSMISSIONS.
SYSTEM: POWER TRAIN; TRANSMISSION SHIFT LINKAGE. CONSEQUENCES OF DEFECT:
SHOULD SEPARATION OCCUR WHILE VEHICLE IS IN OPERATION, LOSS OF VEHICLE
CONTROL, AN ACCIDENT, AND PERSONAL INJURY COULD OCCUR.
NOTE: THE DRIVER IS ADVISED NOT TO OPERATE VEHICLE UNTIL PROPER
ADJUSTMENTS HAVE BEEN MADE.
1982 FORD TRUCK CLUB WAGON 1982 FORD TRUCK E100 1982 FORD TRUCK E150 1982
FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK ECONOLINE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Linkage: > 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Linkage: > 851019 > May > 85 >
A/C Blower Motor - Inoperative > Page 2175
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Shift Linkage: > 851019 > May > 85 >
A/C Blower Motor - Inoperative > Page 2181
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Transmission Cooler: > 842014 > Sep > 84 >
A/T - Oil Cooler Overheating During Cold Weather
Transmission Cooler: Customer Interest A/T - Oil Cooler Overheating During Cold Weather
Article No. 84-20-14
TRANSMISSION - AUTOMATIC - EXTERNAL TRANSMISSION OIL COOLER OVERHEATING
DURING OPERATION IN EXTREMELY COLD WEATHER (-30~F/-34~C) ALL E & F-SERIES EXCEPT F250/ 350 WITH 6.9L DIESEL ENGINE
LIGHT TRUCKS 1982-84 E & F SERIES
Automatic transmission overheating reported on referenced model vehicles operating in low
ambient temperatures of minus 30~F/minus 34~C or below may be the result of reduced fluid flow
through the external oil cooler due to excessive fluid cooling (thickening). This reduced fluid flow
may cause loss of fluid or tranmission overheating.
Symptoms, after low ambient temperatures operation, are as follows:
1. Change in color of transmission fluid.
2. Smell of fluid or evidence of transmission fluid on or under the vehicle.
If the above conditions are noted or if transmission service or replacement is required due to
transmission overheating, the external transmission oil cooler (7A095) must be replaced as shown:
PARTS AFFECTED
VEHICLE USAGE ADD DELETE PART NAME
E100-350 E5UZ-7A095-B (24 Plate) E3UH-7A095-BA Aux. Trans. Oil Cooler Assy.
E250-350 E5UZ-7A095-A (48 Plate) E3UH-7A095-AB Aux. Trans. Oil Cooler Assy.
F100-350 E5TZ-7A095-C (24 Plate) E2TH-7A095-AA Aux. Trans. Oil Cooler Assy.
F250-350 E5TZ-7A095-B (48 Plate) E3TH-7A095-AA Aux. Trans. Oil Cooler Assy.
The new auxiliary transmission oil cooler assembly (7A095) contains an internal bypass which
allows a portion of the transmission fluid to flow more easily through the cooler in extreme cold
weather operations. The new oil cooler continues to provide adequate function during vehicle
operations under normal or warm weather conditions.
The external oil cooler assembly removal and installation procedures for the subject vehicles are as
follows: Removal and Installation:
1. Loosen the two tube compression nuts attaching the two steel tubes to the oil cooler assembly
(7A095) and remove both tubes from the cooler assembly. Remove the oil cooler assembly (a
slight loss of transmission fluid will occur when tubes are disconnected).
2. Install the new cooler assembly to the radiator support. Reconnect the two steel tubes to the
cooler assembly. Securely tighten each tube compression nut to assure a leak-proof connection.
3. Check level of transmission fluid in transmission; add fluid to proper level.
PART NUMBER PART NAME CLASS
E5UZ-7A095-B Aux. Trans. Oil Cooler Assy. R
E5UZ-7A095-A Aux. Trans. Oil Cooler Assy. C
E5TZ-7A095-C Aux. Trans. Oil Cooler Assy. R
E5TZ-7A095-B Aux. Trans. Oil Cooler Assy. C
OTHER APPLICABLE ARTICLES: 84-5-19 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP7095B84 TIME:
0.5 Hr. - E-Series 0.4 Hr. - F-Series DLR. CODING: Basic Part No. 7A095 Code: 55
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 842014 >
Sep > 84 > A/T - Oil Cooler Overheating During Cold Weather
Transmission Cooler: All Technical Service Bulletins A/T - Oil Cooler Overheating During Cold
Weather
Article No. 84-20-14
TRANSMISSION - AUTOMATIC - EXTERNAL TRANSMISSION OIL COOLER OVERHEATING
DURING OPERATION IN EXTREMELY COLD WEATHER (-30~F/-34~C) ALL E & F-SERIES EXCEPT F250/ 350 WITH 6.9L DIESEL ENGINE
LIGHT TRUCKS 1982-84 E & F SERIES
Automatic transmission overheating reported on referenced model vehicles operating in low
ambient temperatures of minus 30~F/minus 34~C or below may be the result of reduced fluid flow
through the external oil cooler due to excessive fluid cooling (thickening). This reduced fluid flow
may cause loss of fluid or tranmission overheating.
Symptoms, after low ambient temperatures operation, are as follows:
1. Change in color of transmission fluid.
2. Smell of fluid or evidence of transmission fluid on or under the vehicle.
If the above conditions are noted or if transmission service or replacement is required due to
transmission overheating, the external transmission oil cooler (7A095) must be replaced as shown:
PARTS AFFECTED
VEHICLE USAGE ADD DELETE PART NAME
E100-350 E5UZ-7A095-B (24 Plate) E3UH-7A095-BA Aux. Trans. Oil Cooler Assy.
E250-350 E5UZ-7A095-A (48 Plate) E3UH-7A095-AB Aux. Trans. Oil Cooler Assy.
F100-350 E5TZ-7A095-C (24 Plate) E2TH-7A095-AA Aux. Trans. Oil Cooler Assy.
F250-350 E5TZ-7A095-B (48 Plate) E3TH-7A095-AA Aux. Trans. Oil Cooler Assy.
The new auxiliary transmission oil cooler assembly (7A095) contains an internal bypass which
allows a portion of the transmission fluid to flow more easily through the cooler in extreme cold
weather operations. The new oil cooler continues to provide adequate function during vehicle
operations under normal or warm weather conditions.
The external oil cooler assembly removal and installation procedures for the subject vehicles are as
follows: Removal and Installation:
1. Loosen the two tube compression nuts attaching the two steel tubes to the oil cooler assembly
(7A095) and remove both tubes from the cooler assembly. Remove the oil cooler assembly (a
slight loss of transmission fluid will occur when tubes are disconnected).
2. Install the new cooler assembly to the radiator support. Reconnect the two steel tubes to the
cooler assembly. Securely tighten each tube compression nut to assure a leak-proof connection.
3. Check level of transmission fluid in transmission; add fluid to proper level.
PART NUMBER PART NAME CLASS
E5UZ-7A095-B Aux. Trans. Oil Cooler Assy. R
E5UZ-7A095-A Aux. Trans. Oil Cooler Assy. C
E5TZ-7A095-C Aux. Trans. Oil Cooler Assy. R
E5TZ-7A095-B Aux. Trans. Oil Cooler Assy. C
OTHER APPLICABLE ARTICLES: 84-5-19 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP7095B84 TIME:
0.5 Hr. - E-Series 0.4 Hr. - F-Series DLR. CODING: Basic Part No. 7A095 Code: 55
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes
Valve Body: Technical Service Bulletins A/T - AOD Separator Plate Gasket Changes
TRANSMISSION - AOD - MAIN CONTROL GASKET CHANGES AFFECTING USAGE OF
SERVICE KITS Article No. 89-23-7 FORD:
1980-90 CROWN VICTORIA 1980-86 LTD 1980-90 THUNDERBIRD 1985-90 MUSTANG
LINCOLN-MERCURY: 1980-87 CONTINENTAL 1980-90 COUGAR, GRAND MARQUIS 1980-83
MARK VI 1980-90 TOWN CAR 1984-90 MARK VII 1985 CAPRI, MARQUIS
LIGHT TRUCK: 1981-90 BRONCO, ECONOLINE, F-150, F-250
ISSUE: The separator plate lower gasket from the current gasket service kit (7153) and overhaul
service kit (7C391) cannot be used on any 1990 model vehicles.
ACTION: When servicing 1990 AOD transmissions the separator plate lower gasket found in the
current kits must be thrown away and replaced with a new gasket (F0AZ-7D100-A). This new
gasket can only be used on 1990 vehicles.
CAUTION: USE OF THE SEPARATOR PLATE LOWER GASKET CONTAINED IN THE
CURRENT KITS ON 1990 VEHICLES COULD
CAUSE A REDUCTION IN THROTTLE VALVE PRESSURE. THIS CAN RESULT IN POSSIBLE
TRANSMISSION FAILURES.
In the near future, gasket and overhaul kits will no longer contain any main control gaskets. Two
main control lower separator plate gasket items will be available. Refer to the following gasket
application chart for correct service part usage.
PART NUMBER PART NAME CLASS
E9AZ-7D100-B Main Control Gasket Kit B
FOAZ-7D100-A Separator Plate Lower Gasket B
E9SZ-7C155-A Main Control Upper Separator B
Plate Gasket
OTHER APPLICABLE ARTICLES: none
SUPERSEDES: 88-13-6
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 5100, 5101, 5102, 5200, 5300, 5500, 5800
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes > Page 2199
Valve Body: Technical Service Bulletins A/T - AOD Main Control Valve Body Gasket
Article No. 86-13-17
TRANSMISSION - AUTOMATIC - AOD - MAIN CONTROL VALVE BODY GASKETS
FORD 1980-86 FORD, THUNDERBIRD, LTD, MUSTANG
LINCOLN-MERCURY 1980-83 MARK VI; 1980-86 MERCURY, COUGAR, MARQUIS, CAPRI,
LINCOLN, CONTINENTAL; 1984-86 MARK VII
LIGHT TRUCK 1981-86 E SERIES, F SERIES, BRONCO
Figure 11
Figure 12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes > Page 2200
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes > Page 2201
Valve Body: Technical Service Bulletins A/T - AOD Orifice Control Valve Plug Retainer
Article No. 85-14-7
TRANSMISSION - AUTOMATIC - AOD - ORIFICE CONTROL VALVE PLUG RETAINER
CHANGE
FORD 1980-85 FORD, THUNDERBIRD, LTD, MUSTANG
LINCOLN-MERCURY 1980-85 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, MARK,
CONTINENTAL
LIGHT TRUCK 1981-85 E & F SERIES - BRONCO
An improved plug retainer design is available for the orifice control valve bore plug in the AOD main
control valve body assembly. A retainer plate (E5AZ-7E335-A) replaces the hairpin clip.
NOTE: Whenever the AOD main control valve body is disassembled for service, replace the hairpin
clip with the retainer plate. For location of the orifice control valve bore, refer to the AOD main
control assembly/disassembly section of the Car or Truck Shop Manual.
PART NUMBER PART NAME CLASS
E5AZ-7E335-A Retainer Plate R
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information >
Adjustments
Clutch Pedal Assembly: Adjustments
NOTE: Clutch pedal total travel is not adjustable on these models.
1. Check clutch pedal free travel by measuring distance from clutch pedal pad to steering wheel
rim, then depress clutch pedal until free travel is
diminished and take a second measurement. If the difference between the two measurements is
less than 1/2 inch, the clutch linkage must be adjusted.
2. Loosen and back off the two jam nuts several turns, then adjust the first jam nut until a free travel
measurement of 1 and 1/2 inches is obtained at
the clutch pedal.
3. While holding the second jam nut, tighten the first jam nut against the second one. 4. Recheck
free pedal travel and readjust as necessary.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Switch <--> [Clutch Switch] >
Component Information > Testing and Inspection
Clutch Pedal Position Switch: Testing and Inspection
Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized
tools near this switch.
1. If the switch is open when the clutch pedal is released, speed control will not operate. This must
be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher
when performing the clutch switch test.
2. Disconnect switch pigtail connector from speed control harness connector and connect an
ohmmeter to the two switch connector terminals.
3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With
clutch pedal fully depressed, the circuit should be open.
4. If switch does not function as described, remove and replace switch.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component
Information > Technical Service Bulletins > Customer Interest for Clutch Release Bearing: > 85214 > Jan > 85 > Clutch Release Bearing Squeak/Scrape
Clutch Release Bearing: Customer Interest Clutch - Release Bearing Squeak/Scrape
Article No. 85-2-14
CLUTCH - RELEASE BEARING SQUEAK/SCRAPE
LIGHT TRUCKS 1982-83 E & F150-350, BRONCO
The concern is usually characterized by a squeal which occurs with the engine running and light
pressure applied to the clutch pedal. The squeal stops when greater force is applied to the pedal,
which occurs when disengaging the clutch. Under light pedal pressure, the release bearing load is
insufficient to overcome the friction of the stationary bearing, and metal to metal squeal/scrape
results between the bearing and the rotating pressure plate. Under greater axial loads, the bearing
rotates with the pressure plate, and the squeal stops.
Major factors which tend to increase the tendency for a release bearing to squeal are as follows: 1.
Insufficient free play.
2. Lack of clutch housing concentricity and parallelism.
3. Out of plane pressure fingers.
The recommended respective diagnostic/service procedure for the above factors are as follows: 1.
Check clutch linkage free play per Section 16-03 of 1983 Light Truck Shop Manual.
2. Check clutch housing bore and face run out per Shop Manual procedure Section 16-01.
3. Check pressure plate finger heights per Shop Manual procedure Section 16-01.
Replace bearing if all of the above have been investigated and found acceptable. Customers also
should be advised that light pedal pressure may result in squeal at the onset of clutch engagement
with the free play type clutch linkage system.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP7003D83 TIME:
0.8 Hr. (Plus applicable standard times) DLR. CODING: Basic Part No. 7580 Code: 56
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Release Bearing: > 85214 > Jan > 85 >
Clutch - Release Bearing Squeak/Scrape
Clutch Release Bearing: All Technical Service Bulletins Clutch - Release Bearing Squeak/Scrape
Article No. 85-2-14
CLUTCH - RELEASE BEARING SQUEAK/SCRAPE
LIGHT TRUCKS 1982-83 E & F150-350, BRONCO
The concern is usually characterized by a squeal which occurs with the engine running and light
pressure applied to the clutch pedal. The squeal stops when greater force is applied to the pedal,
which occurs when disengaging the clutch. Under light pedal pressure, the release bearing load is
insufficient to overcome the friction of the stationary bearing, and metal to metal squeal/scrape
results between the bearing and the rotating pressure plate. Under greater axial loads, the bearing
rotates with the pressure plate, and the squeal stops.
Major factors which tend to increase the tendency for a release bearing to squeal are as follows: 1.
Insufficient free play.
2. Lack of clutch housing concentricity and parallelism.
3. Out of plane pressure fingers.
The recommended respective diagnostic/service procedure for the above factors are as follows: 1.
Check clutch linkage free play per Section 16-03 of 1983 Light Truck Shop Manual.
2. Check clutch housing bore and face run out per Shop Manual procedure Section 16-01.
3. Check pressure plate finger heights per Shop Manual procedure Section 16-01.
Replace bearing if all of the above have been investigated and found acceptable. Customers also
should be advised that light pedal pressure may result in squeal at the onset of clutch engagement
with the free play type clutch linkage system.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP7003D83 TIME:
0.8 Hr. (Plus applicable standard times) DLR. CODING: Basic Part No. 7580 Code: 56
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Component Information > Testing and Inspection > Bearing Cups
Carrier Bearings: Testing and Inspection Bearing Cups
Check bearing cups for rings, spalling, galling or erratic wear patterns. The bearing cups must be
solidly seated. Check by attempting to insert .0015 inch feeler gauge between cups and bottoms of
bores.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Component Information > Testing and Inspection > Bearing Cups > Page 2228
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Component Information > Testing and Inspection > Bearing Cups > Page 2229
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears >
Component Information > Testing and Inspection
Carrier Side Gears: Testing and Inspection
Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot
be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock
loading or the use of improper lubricant. Scored gears cannot be reused.
Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may
cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of
splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Testing and Inspection
Differential Case: Testing and Inspection
Ensure that hubs where bearings mount are smooth. Check fit of differential gears in the
counterbores. Carefully examine thrust washers, which may be damaged when bearings are
removed. If differential bearing assemblies do not seat firmly on hubs, failure is certain. Ensure that
mating surfaces of the two parts of case and the face of the ring gear attaching flange are smooth
and free from nicks and burrs.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Testing and Inspection > Page 2236
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Testing and Inspection > Page 2237
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly
Differential Axle Housing: Service and Repair Dana/Spicer Integral - Rear Axle Assembly
1. Raise vehicle from floor and support with stand jacks under frame side rails.
2. Remove rear wheels.
3. Split rear universal joint.
4. Disconnect parking brake cable from equalizer rod and unfasten brake cable brackets from
frame crossmember.
5. Disconnect hydraulic brake line connection at rear axle housing.
6. Loosen and move shock absorbers out of the way.
7. While supporting axle housing with hydraulic jack, remove spring clips and lower axle assembly
to the floor.
8. Reverse the foregoing procedure to install the rear axle assembly, being sure to bleed the brake
system when the installation is completed.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2242
Differential Axle Housing: Service and Repair Ford Integral Carrier
Axle Disassembly, Ford Integral Carrier
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2243
Fig. 1 Disassembled view of Ford 6 3/4 inch ring gear axle
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2244
Fig. 2 Disassembled view of Ford 7 1/2 inch ring gear axle
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2245
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2246
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2247
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage
Fluid - Differential: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2252
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2253
Fluid - Differential: Technical Service Bulletins Front/Rear Drive Axles - Lubricant Drain/Fill
Procedure
Article No. 83-3-23
FRONT AND REAR DRIVE AXLES - LUBRICANT DRAIN AND FILL PROCEDURE
LIGHT TRUCKS 1979-83 F100-350, BRONCO, E100-350, RANGER, BRONCO II
The following is the recommended procedure for draining axle lubricant from front and/or rear
driving axles on all light truck models.
1. Drive the vehicle for 10-15 miles at highway speed to warm axle lubricant to operating
temperature and minimum viscosity.
2. Raise the vehicle on a hoist and place a drain pan under the axle to be drained.
3. Wire brush the filler plug area of the axle housing cover or carrier assembly to prevent possible
entry of dirt, rust, etc. into the axle assembly.
4. Remove the axle lubricant fill plug.
5. Using a suitable suction-type utility pump (manual or powered), drain the axle lubricant from the
axle by inserting the pump suction hose through axle filler plug hole down into the lowest portion of
the axle carrier housing removing all the lubricant.
6. Fill the axle housing with the specified amount and type of lubricant as shown on the following
specification charts.
7. Install the filler plug and torque as shown on the following specification charts.
FRONT/REAR DRIVING AXLE SPECIFICATION CHARTS
I. Filler Rug Torque Chart
Axle Fill Plug Torque All Dana Front/Rear 20-30 Ft.Lbs.
- Ford Built Rear Axles 25-50 Ft.Lbs.
II. Axle Lubricant Capacities - Econoline
Approximate Capacity (1) U.S. Pints (2) Ford Standard and Traction-Lok
5.5 (3)
(E-100/150)
Dana Standard and Limited Slip 6.0 (4)
(E-250, Model 60/61-2)
Dana Standard and Limited Slip 6.5 (4)
(Model 70), Dual Rear Wheels
Ford Standard and Traction-Lok 5.5
(E-250 Van)
Dana Standard and Limited Slip 6.0 (4)
(Model 61-1) Single Rear Wheels
(1) Service refill capacities are determined by filling to the bottom of the filler hole.
(2) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A All Dana Conventional and Limited-Slip Rear Axles - Use ESW-M2C105-A
(3) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford
TractionLok axle.
(4) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana
Rear Limited-Slip Axle.
III. Axle Lubricant Capacities - Bronco Chart
Approximate Capacity (1) U.S. Pints Front Axle (5) Dana
3.8 (3)
Rear Axle (4) Ford 5.5 (2)
(1) Refill Capacity is determined by filling to the bottom of the filler hole.
(2) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A.
(3) All Dana Conventional and Limited-Slip Front Drive
Axles - Use ESW-M2C105-A.
(4) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford
TractionLok Axle (1979-1982).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2254
(5) Add 2 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana
Front Limited-Slip Axle.
IV. Axle Lubricant Capacities - F100 - F350 (4x2/4x4)
Approximate Capacity (1) U.S. Measure Axle Model (4)
Truck Type (Pints)
Ford 8.8" and 9" F100/150/250 5.5 (3)
Dana 44-IFS (Front Axle) F150/250 (4x4) 3.8
Dana 60 (Rear) F250 6.0
Dana 61-2 (Rear) F250 6.0
Dana 50-IFS (Front Axle) F250/350 (4x4) Heavy 4.1
Duty & Snow Plow
Dana 70 (Rear) F350 DRW Chassis Cab 6.5
Dana 70 HD (Rear) F350 DRW Regular Cab 7.4
Dana 61-1 (Rear F250/350 SRW 6.0
(1) Service refill capacities are determined by filling to the
bottom of the filler hole.
(2) Add EST-M2C118-A (Friction Modifier Part No. C8AZ-19B546-A) for complete refill of Dana
LimitedSlip axles. Add 4 ounces for F250/350 Rear. For F150 & F250 4x4 add 2 ounces to front
axle.
(3) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford
TractionLok Axle (1979-1982).
(4) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A. All Dana Conventional and Limited-Slip Front/Rear Axles - Use
ESW-M2C105-A.
V. Axle Lubricant Capacities - Ranger 4x2/4x4, Bronco II
Approximate Capacities
U.S. Imperial
Measure Measure
(Pints) (Pints) Liters
Rear Ford 6-3/4 Ring Gear (1)(4) 3.0 2.5 1.4
Rear Ford 7.5 Ring Gear (2)(4) 5.0 (6) 4.2 2.4
Dana 28 Front Axle (4x4 Only)(3)(5) 1.0 (7) 0.83 0.45
Bronco II Ford 7.5 Ring Gear(2)(4) 5.5 (6) 4.6 2.6
(1) Fill to 3/8 in. +/- 1/8 in. (9.5 mm +/- 3 mm) below bottom of fill hole. Base GVW axle with 2.0L
engine and 2.3L engine with automatic.
(2) Fill to 1/2 in. +/- 1/8 in. (12.7 mm t 3 mm) below bottom of fill hole. Optional GVW or 2.3L
engine.
(3) Fill to 1/2 in. +/- 1/8 in. (12.7 mm + 3 mm) below bottom of fill hole.
(4) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A.
(5) All Dana Conventional and Limited-Slip Front Axles - Use ESW-M2C105-A.
(6) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford
TractionLok Axle.
(7) Add 1/2 ounce of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana
Front Limited-Slip Axle.
PART NUMBER PART NAME CLASS
E0AZ-19580-A Lubricant-ESP-M2C154-A AM
C6AZ-19580-E Lubricant-ESW-M2C105-A AG
C8AZ-19B546-A Friction Modifier-EST-M2C118-A A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
TYPE: Standard 90 HP
Limited-Slip 90 HP*
CAPACITY, Refill: Front: All models 4.0 pt (US)
LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Letter &
number on plate on door lock pillar
Rear: Dana 60 5.0 pt (US)
Dana 61 6.0 pt (US)
1982 70 HD 7.4 pt (US)
1981 Econoline w/Dana 70 7.0 pt (US)
Others 6.5 pt (US)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 2257
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Bearing Cups
Pinion Bearing: Testing and Inspection Bearing Cups
Check bearing cups for rings, galling or erratic wear patterns. The bearing cups must be solidly
seated. Check by attempting to insert .0015 inch feeler gauge between cups and bottoms of bores.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Bearing Cups > Page 2262
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Bearing Cups > Page 2263
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Bearing Cups > Page 2264
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Bearing Cups > Page 2265
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Page 2266
Pinion Bearing: Adjustments
Fig. 4 Shim replacement for preload adjustment
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Page 2267
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle
Pinion Bearing: Service and Repair Dana/Spicer, Rear Axle
Pinion Bearing Cup Installation, DANA/SPICER, REAR AXLE
1. Place inner and outer bearing cups into carrier bore.
2. Install suitable inner bearing cup replacer tool on the inner bearing cup.
3. Install suitable outer bearing cup replacer tool on the outer bearing cup.
4. Install suitable threaded draw bar into the replacer tools, then tighten the draw bar to install cups
into carrier bore.
Pinion Bearing Preload & Final Depth Check, REAR AXLE
Fig. 4 Shim replacement for preload adjustment
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2270
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2271
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2272
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2273
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2274
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2275
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2276
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Technical Service Bulletins > Rear Axle - Pinion Angle Adjustments
Pinion Gear: Technical Service Bulletins Rear Axle - Pinion Angle Adjustments
Article No. 85-5-28
REAR AXLE PINION ANGLE ADJUSTMENTS
LIGHT TRUCK 1976-85 E & F 100-350 AND BRONCO
Whenever the rear axle pinion angle requires adjustment to bring it into specification, the following
tapered shims should be installed as outlined in the 1985 Light Truck Shop Manual, Section
14-31-2. Part Number
Part Number Angle Degree Application Class
C3TZ-5A313-A 2.5" Wide Shim 2 F-100/150 C
C3TZ-5A313-E (Ford Axles) 3 Bronco R
E100/150
C6TZ-5A313-B 3.0" Wide Shim 3 F-250/350 BM
(Dana Axles) E-250/350
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Technical Service Bulletins > Rear Axle - Pinion Angle Adjustments > Page 2281
Pinion Gear: Technical Service Bulletins Differential Pinion Bolt - Removal Aid
Article No. 84-6-15
AXLE - FORD-BUILT CAST CENTER AXLES - AID TO BOLT REMOVAL PROCEDURE FOR
DIFFERENTIAL PINION SHAFT LOCK BOLT
FORD
1977-84 FORD CARLINES WITH 7.5", 8.5", 8.7", 8.8" REAR AXLES
LINCOLN-MERCURY 1977-84 LINCOLN-MERCURY CARLINES WITH 7.5", 8.5", 8.7", 8.8" REAR
AXLES
LIGHT TRUCKS 1977-84 LIGHT TRUCKS WITH 7.5", 8.8" REAR AXLES
The subject bolt head may round off during removal with a conventional wrench or socket. To
eliminate this condition, a socket type wrench may be made from a 3/8-inch Allen head bolt and a
steel rod.
FIGURE 12
Cut the Allen head from the bolt and weld the head to the 6" rod. The rod will serve as a handle
(Figure 12). In addition, the recess in the Allen head fits the 5/16-inch head in the differential pinion
shaft lock bolt precisely.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Technical Service Bulletins > Page 2282
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Adjustments > Depth Gauge Check
Pinion Gear: Adjustments Depth Gauge Check
If any of the gauge surfaces become nicked, the high spots should be removed using an oil stone.
1. Install a new rear pinion bearing over a suitable aligning adapter, then position into the pinion
bearing retainer assembly.
2. Place front of pinion bearing into the bearing cup, then assemble the handle onto the screw and
hand tighten. The square drive in the handle of the tool is to be used for obtaining the proper pinion
bearing preload. Set preload to 20---40 inch lbs.
3. Center suitable gauge tube into the differential bearing bore, then install the differential bearing
caps.
4. Using a feeler gauge tool or shims, select the thickest shim that will enter between the gauge
tube and gauge block. Insert feeler gauge directly along the gauge block to ensure a correct
reading. If the service pinion gear is marked with a plus (+) reading, this amount should be
subtracted from the thickness dimension obtained in step 4. If the service pinion gear is marked
with a minus ( - ) reading, this amount should be added to the thickness dimension obtained in step
4.
5. Remove inner pinion bearing cup and install the correct number of shims in the carrier bore.
6. Install bearing cup and oil slinger, if equipped, on the pinion, then press on bearing using a
suitable tool. If a baffle or slinger is used, replace with a new one during assembly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Adjustments > Depth Gauge Check > Page 2285
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Adjustments > Depth Gauge Check > Page 2286
Pinion Gear: Adjustments Pinion Bearing Preload & Final Depth Check
Fig. 4 Shim replacement for preload adjustment
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Adjustments > Depth Gauge Check > Page 2287
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle
Pinion Gear: Service and Repair Dana/Spicer, Rear Axle
Depth Gauge Check, Dana/Spicer, Rear Axle
If any of the gauge surfaces become nicked, the high spots should be removed using an oil stone.
1. Install a new rear pinion bearing over a suitable aligning adapter, then position into the pinion
bearing retainer assembly.
2. Place front of pinion bearing into the bearing cup, then assemble the handle onto the screw and
hand tighten. The square drive in the handle of the tool is to be used for obtaining the proper pinion
bearing preload. Set preload to 20---40 inch lbs.
3. Center suitable gauge tube into the differential bearing bore, then install the differential bearing
caps.
4. Using a feeler gauge tool or shims, select the thickest shim that will enter between the gauge
tube and gauge block. Insert feeler gauge directly along the gauge block to ensure a correct
reading. If the service pinion gear is marked with a plus (+) reading, this amount should be
subtracted from the thickness dimension obtained in step 4. If the service pinion gear is marked
with a minus ( - ) reading, this amount should be added to the thickness dimension obtained in step
4.
5. Remove inner pinion bearing cup and install the correct number of shims in the carrier bore.
6. Install bearing cup and oil slinger, if equipped, on the pinion, then press on bearing using a
suitable tool. If a baffle or slinger is used, replace with a new one during assembly.
Drive Pinion Depth of Mesh Setting, Dana/Spicer, Rear Axle
Fig. 3 Shim setting chart
Ring gears and pinions are supplied in matched sets only. Matched numbers on both the pinion
and ring gear are etched for verification. On the face of each pinion there is etched either a plus or
a minus number, or ``0,'' which indicates the best running position for each particular gear set. This
dimension is controlled by shimming behind the inner pinion bearing cup. A pinion etched with a +3
would require .003 inch less shims that a pinion etched ``0.'' A pinion etched - 3 would require .003
inch more shims than a pinion etched ``0.'' If the etched figure is ``0'' the shim pack will remain the
same. Refer to chart, Fig. 3. Shims are available in thicknesses of .003 inch, .005 inch, .010 inch
and .030 inch.
If old ring and pinion set is to be reused, measure the old shim pack and build a new shim pack to
the same dimension. If a baffle is used in the axle assembly, it is considered a part of the shim
pack. Measure each shim separately with a micrometer and add together to get the total shim pack
thickness from the original build up.
If a new gear set is being used, notice the (+) or ( - ) etching on both the new and old pinion and
adjust thickness of new shim pack to compensate for the difference of these two figures. For
example, if the old pinion reads +2 and the new pinion is - 2, add .004 inch shims to the original
shim pack.
Pinion Bearing Preload & Final Depth Check, Rear Axle
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2290
Fig. 4 Shim replacement for preload adjustment
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2291
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2292
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2293
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2294
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2295
Selecting Correct Pinion Shim, Ford Removable Carrier
Fig. 5 Removable carrier 9 inch ring gear axle pinion depth tool gauge
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2296
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Testing and Inspection > Gears
Ring Gear: Testing and Inspection Gears
Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot
be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock
loading or the use of improper lubricant. Scored gears cannot be reused.
Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may
cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of
splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Testing and Inspection > Gears > Page 2301
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Adjustments > Assembly of Differential Into Housing
Ring Gear: Adjustments Assembly of Differential Into Housing
Ring Gear & Pinion Backlash
1. Position differential assembly, with pinion installed, into housing. Ensure master bearings are still
assembled in case.
2. Install dial indicator on carrier housing in same location as when spreading case.
3. Force ring gear into mesh with pinion, then set dial indicator to ``0'' while maintaining force on
differential case.
4. Force ring gear away from pinion gear and note dial reading. Repeat sequence until same
indicator reading is obtained. This measurement indicates amount of shims needed between
differential case and bearings on the ring gear side.
5. Remove dial indicator and differential case from carrier, then the master bearings from
differential case.
6. Place shims determined in step 4 on ring gear hub of differential case.
7. Install bearing cone on ring gear side of differential case, then drive bearing into place.
8. To determine thickness of shims required on hub of drive pinion side of differential case, subtract
thickness of shims installed in step 6 from total differential case endplay as measured in
``Differential Case Assembly'' procedure. To this figure, add .015 inch.
9. Place shims determined in step 8 on hub of drive pinion side of differential case.
10. Install bearing cone on hub of drive pinion side of differential case.
11. Position suitable step plate on ring gear side bearing to protect bearing.
12. Place bearing on drive pinion side hub and drive it into position.
13. Install spreader tool and dial indicator as previously described. Do not spread case more than
.015 inch.
14. Assemble differential bearing cups to bearing cones, then install differential assembly into
carrier.
15. Tap differential assembly into position in carrier using a soft-faced hammer, then remove
spreader tool from case.
16. Install bearing caps in proper position, then torque cap screws to 80---90 ft. lbs. on except
model 30 axle or 35---50 ft. lbs on model 30 axle.
17. Measure ring gear and pinion backlash at three equidistant points using a dial indicator.
Backlash must measure .004---.009 inch on except model 30 axle or .005---.009 inch on model 30
axle and cannot vary more than .003 inch on except model 30 axle or .002 inch on model 30 axle
between points checked. Backlash may be brought within specifications by switching shims from
one side of differential case to the other. Move ring gear closer to pinion to correct high backlash,
or further away from pinion to correct low backlash.
18. On except model 30 axle having a cover plate without a flat mounting surface, install cover
plate, using a new gasket, and torque attaching bolts alternately and evenly to 30---40 ft. lbs. On
model 30 axle, torque cover attaching bolts to 15---25 ft. lbs.
19. On units having a cover plate with a flat mounting surface, install cover as follows:
a. Clean flat surface of cover plate and carrier mating surface. b. Apply suitable sealant to cover
plate surface, ensuring bead of sealant is laid on inside of cover screw holes. c. Install two
attaching bolts into cover at 2 o'clock and 8 o'clock positions. d. Position cover on carrier, then
install remaining attaching bolts. e. Torque all attaching bolts alternately and evenly to 30---40 ft.
lbs.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Adjustments > Assembly of Differential Into Housing > Page 2304
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Service and Repair > Dana/Spicer Integral Housing Type
Axle Bearing: Service and Repair Dana/Spicer Integral Housing Type
Full-Floating Axle
1. Set parking brake and loosen axle shaft bolts.
2. Raise and support rear of vehicle so that axle is parallel with floor.
3. Remove axle shaft bolts.
4. Remove axle shaft and discard gasket.
5. Pry out locking wedge with screwdriver.
6. Raise wheel until weight is removed from wheel bearing.
7. Remove wheel bearing adjustment nut.
8. Remove outer bearing cone and pull wheel assembly from axle.
9. Drive inner bearing cone and seal out of wheel hub with brass drift.
10. Inspect bearings and races and replace if worn or damaged. Drive races from wheel hub with
brass drift.
11. Lubricate bearing cone and roller assemblies and place inner assemblies into wheel hub. Install
new hub inner seal.
12. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and
remove tape.
13. Install outer wheel bearing and start adjuster nut. Lower wheel to ground.
14. While rotating wheel, torque adjusting nut to 120-140 ft. lbs. Back off the nut to obtain
0.001---0.010 inch endplay (1/8-3/8 turn). If nut or locking wedge are damaged or do not allow for
proper endplay they should be replaced.
15. Position locking wedge in key way slot, making sure it is not bottomed against the shoulder of
adjusting nut.
16. Install axle shaft and new flange gasket, then install retaining bolts and torque locking bolts to
40---50 ft. lbs.
17. Adjust brakes.
18. Remove supports and lower vehicle.
Semi-Floating Axle
1. Raise and support vehicle.
2. Remove wheel and brake drum.
3. Remove cover plate and discard gasket.
4. Remove differential pinion shaft lock screw and the shaft.
5. Remove C-clip from button end of shaft by pushing inward on other end.
6. Pull shaft from axle tube. Do not rotate differential side gears.
7. Remove and discard oil seal from axle tube.
8. Pull bearing from axle tube.
9. Lubricate new bearing and install in axle tube.
10. Lubricate and install new oil seal.
11. Insert shaft into axle tube, making sure splines engage side gears, then install C-clip and pull
shaft outward until the clip locks.
12. Install pinion mate shaft, aligning lock pin holes, and pinion gear side washers.
13. Install new lock screw and torque to 8 ft. lbs. on 1980---81 models, or 20---25 ft. lbs. on
1982---87 models.
14. Install cover plate and gasket. Torque bolts to 30---40 ft. lbs.
15. Install wheel and drum assembly.
16. Remove supports and lower vehicle.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 2310
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 2311
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type
Axle Shaft: Service and Repair Dana/Spicer Integral Housing Type
Full-Floating Axle
1. Set parking brake and loosen axle shaft bolts.
2. Raise and support rear of vehicle so that axle is parallel with floor.
3. Remove axle shaft bolts.
4. Remove axle shaft and discard gasket.
5. Pry out locking wedge with screwdriver.
6. Raise wheel until weight is removed from wheel bearing.
7. Remove wheel bearing adjustment nut.
8. Remove outer bearing cone and pull wheel assembly from axle.
9. Drive inner bearing cone and seal out of wheel hub with brass drift.
10. Inspect bearings and races and replace if worn or damaged. Drive races from wheel hub with
brass drift.
11. Lubricate bearing cone and roller assemblies and place inner assemblies into wheel hub. Install
new hub inner seal.
12. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and
remove tape.
13. Install outer wheel bearing and start adjuster nut. Lower wheel to ground.
14. While rotating wheel, torque adjusting nut to 120-140 ft. lbs. Back off the nut to obtain
0.001---0.010 inch endplay (1/8-3/8 turn). If nut or locking wedge are damaged or do not allow for
proper endplay they should be replaced.
15. Position locking wedge in key way slot, making sure it is not bottomed against the shoulder of
adjusting nut.
16. Install axle shaft and new flange gasket, then install retaining bolts and torque locking bolts to
40---50 ft. lbs.
17. Adjust brakes.
18. Remove supports and lower vehicle.
Semi-Floating Axle
1. Raise and support vehicle.
2. Remove wheel and brake drum.
3. Remove cover plate and discard gasket.
4. Remove differential pinion shaft lock screw and the shaft.
5. Remove C-clip from button end of shaft by pushing inward on other end.
6. Pull shaft from axle tube. Do not rotate differential side gears.
7. Remove and discard oil seal from axle tube.
8. Pull bearing from axle tube.
9. Lubricate new bearing and install in axle tube.
10. Lubricate and install new oil seal.
11. Insert shaft into axle tube, making sure splines engage side gears, then install C-clip and pull
shaft outward until the clip locks.
12. Install pinion mate shaft, aligning lock pin holes, and pinion gear side washers.
13. Install new lock screw and torque to 8 ft. lbs. on 1980---81 models, or 20---25 ft. lbs. on
1982---87 models.
14. Install cover plate and gasket. Torque bolts to 30---40 ft. lbs.
15. Install wheel and drum assembly.
16. Remove supports and lower vehicle.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 2317
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 2318
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair
Seals and Gaskets: Service and Repair
Removal, Units w/Ball Bearing
1. Remove wheel assembly.
2. Remove brake drum from flange.
3. Working through hole provided in axle shaft flange, remove nuts that secure wheel bearing
retainer.
4. Pull axle shaft out of housing. If bearing is a tight fit in axle housing, use a slide hammer type
puller.
5. Remove brake backing plate and secure to frame rail.
6. If the axle shaft bearing is to be replaced, loosen the inner retainer by nicking it deeply with a
chisel in several places. The bearing will then slide off easily.
7. Press bearing from axle shaft.
8. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing
action of the oil seal. Carefully remove any burrs or rough spots.
Installation
1. Press new bearing on shaft until it seats firmly against shoulder on shaft.
2. Press inner bearing retainer on shaft until it seats firmly against bearing.
3. If oil seal is to be replaced, use a hook-type tool to pull it out of housing. Wipe a small amount of
oil resistant sealer on outer edge of seal before it is installed.
Removal, Units W/Roller Bearing
1. Remove wheel assembly.
2. Remove brake drum from flange.
3. Working through hole provided in axle flange, remove nuts securing wheel bearing retainer.
4. Pull axle shaft carefully from housing to prevent damage to outer seal rubber. Use a slide
hammer type puller to remove tapered bearing cup from housing. Remove brake backing plate and
secure to frame rail.
5. If the axle shaft bearing or seal is to be replaced, split the inner bearing retainer.
6. Press bearing from axle shaft.
7. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing
action of the oil seal. Carefully remove any burrs or rough spots.
8. Install outer retainer plate on axle shaft. Press lubricated seal and bearing onto shaft until firmly
seated. Oil seal for rear drum brake equipped vehicles is different than that used on vehicles with
rear disc brakes. Seals used with drum brakes have a gray metal colored outer rim, while seals
used with disc brakes have a black or orange color.
9. Press new bearing retainer onto shaft until seated.
Installation
1. On 1980---84 models, place a new gasket on each side of brake carrier plate, and slide axle
shaft into housing. On models with roller bearing, ensure outer seal is fully seated on bearing.
2. Start splines into differential side gear and push shaft in until bearing bottoms in housing.
3. Torque bearing retainer nuts to 20---40 ft. lbs.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Adjustments
Wheel Bearing: Adjustments
EXCEPT 4 WHEEL DRIVE MODELS
1. Remove wheel and tire assembly, disc brake caliper and pads, dust cap, locknut, adjusting nut,
washer and cotter pin.
2. Tighten wheel adjusting nut to 22-25 ft. lbs. while rotating disc brake rotor in opposite direction.
3. Back off wheel retention nut 1/8 turn and install retainer and cotter pin without any additional
movement of nut.
4. Reinstall dust cap, caliper, pads and tire and wheel assembly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Adjustments > Page 2325
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Technical Service Bulletins > Recalls for Axle Nut: > NHTSA82V104000 > Oct > 82 > recall
82V104000: Rear Axle Nut Inspection
Axle Nut: Recalls recall 82V104000: Rear Axle Nut Inspection
ON CERTAIN VEHICLES, THE LOCK WEDGES USED TO SECURE THE AXLE BEARING NUTS
TO THE AXLE HOUSING MAY FALL OUT OF POSITION, ALLOWING THE NUT TO LOOSEN.
THE NUT ON THE LEFT SIDE MAY FALL OFF, ALLOWING MOVEMENT OF THE AXLE SHAFT.
THE DEALER WILL REPLACE DEFECTIVE LOCK WEDGES WITH AN IMPROVED VERSION.
WHEEL BEARINGS WILL BE INSPECTED AND ADJUSTED OR REPLACED, IF NECESSARY.
VEHICLE DESCRIPTION: LIGHT TRUCKS WITH DANA FULL-FLOATING REAR AXLES.
SYSTEM: POWER TRAIN; REAR AXLE ASSEMBLY. CONSEQUENCES OF DEFECT: THIS
COULD RESULT IN PARTIAL LOSS OF BRAKING ACTION OR PARTIAL OR TOTAL
SEPARATION OF THE LEFT REAR WHEEL AND BRAKE ASSEMBLY.IN EITHER CASE, LOSS
OF VEHICLE CONTROL AND AN ACCIDENT COULD FOLLOW.
1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK F250 1982 FORD
TRUCK F350 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK F250
1983 FORD TRUCK F350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > NHTSA82V104000 >
Oct > 82 > recall 82V104000: Rear Axle Nut Inspection
Axle Nut: All Technical Service Bulletins recall 82V104000: Rear Axle Nut Inspection
ON CERTAIN VEHICLES, THE LOCK WEDGES USED TO SECURE THE AXLE BEARING NUTS
TO THE AXLE HOUSING MAY FALL OUT OF POSITION, ALLOWING THE NUT TO LOOSEN.
THE NUT ON THE LEFT SIDE MAY FALL OFF, ALLOWING MOVEMENT OF THE AXLE SHAFT.
THE DEALER WILL REPLACE DEFECTIVE LOCK WEDGES WITH AN IMPROVED VERSION.
WHEEL BEARINGS WILL BE INSPECTED AND ADJUSTED OR REPLACED, IF NECESSARY.
VEHICLE DESCRIPTION: LIGHT TRUCKS WITH DANA FULL-FLOATING REAR AXLES.
SYSTEM: POWER TRAIN; REAR AXLE ASSEMBLY. CONSEQUENCES OF DEFECT: THIS
COULD RESULT IN PARTIAL LOSS OF BRAKING ACTION OR PARTIAL OR TOTAL
SEPARATION OF THE LEFT REAR WHEEL AND BRAKE ASSEMBLY.IN EITHER CASE, LOSS
OF VEHICLE CONTROL AND AN ACCIDENT COULD FOLLOW.
1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK F250 1982 FORD
TRUCK F350 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK F250
1983 FORD TRUCK F350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <-->
[Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest for Propeller Shaft: >
872218 > Nov > 87 > Driveline - Clunk/Grunt Noise On Start Up
Propeller Shaft: Customer Interest Driveline - Clunk/Grunt Noise On Start Up
Article No. 87-22-18
^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND
STOPPING
^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING
LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87
AEROSTAR
This article is being republished in its entirety to clarify the slip yoke application chart.
ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive
modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the
transmission output shaft splines. During the same drive modes, rear suspension wrap-up
overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which
results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6
transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission;
1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2)
and 1986-87 Aerostar.
ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for
smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke
removal and installation procedures. Also, refer to the slip yoke application chart below for the
correct service part number.
PART NUMBER PART NAME CLASS
E6TZ-4841-D Slip Yoke C
E6TZ-4841-E Slip Yoke C
E6TZ-4841-F Slip Yoke C
E4TZ-4841-G Slip Yoke B
E1TZ-4841-D Slip Yoke B
D5UZ-4841-C Slip Yoke B
OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible
Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part
No. 4841 - Code: 41
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <-->
[Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Propeller
Shaft: > 872218 > Nov > 87 > Driveline - Clunk/Grunt Noise On Start Up
Propeller Shaft: All Technical Service Bulletins Driveline - Clunk/Grunt Noise On Start Up
Article No. 87-22-18
^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND
STOPPING
^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING
LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87
AEROSTAR
This article is being republished in its entirety to clarify the slip yoke application chart.
ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive
modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the
transmission output shaft splines. During the same drive modes, rear suspension wrap-up
overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which
results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6
transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission;
1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2)
and 1986-87 Aerostar.
ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for
smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke
removal and installation procedures. Also, refer to the slip yoke application chart below for the
correct service part number.
PART NUMBER PART NAME CLASS
E6TZ-4841-D Slip Yoke C
E6TZ-4841-E Slip Yoke C
E6TZ-4841-F Slip Yoke C
E4TZ-4841-G Slip Yoke B
E1TZ-4841-D Slip Yoke B
D5UZ-4841-C Slip Yoke B
OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible
Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part
No. 4841 - Code: 41
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 872218 > Nov > 87 > Driveline Clunk/Grunt Noise On Start Up
Slip Yoke: Customer Interest Driveline - Clunk/Grunt Noise On Start Up
Article No. 87-22-18
^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND
STOPPING
^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING
LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87
AEROSTAR
This article is being republished in its entirety to clarify the slip yoke application chart.
ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive
modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the
transmission output shaft splines. During the same drive modes, rear suspension wrap-up
overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which
results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6
transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission;
1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2)
and 1986-87 Aerostar.
ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for
smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke
removal and installation procedures. Also, refer to the slip yoke application chart below for the
correct service part number.
PART NUMBER PART NAME CLASS
E6TZ-4841-D Slip Yoke C
E6TZ-4841-E Slip Yoke C
E6TZ-4841-F Slip Yoke C
E4TZ-4841-G Slip Yoke B
E1TZ-4841-D Slip Yoke B
D5UZ-4841-C Slip Yoke B
OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible
Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part
No. 4841 - Code: 41
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 831623 > Aug > 83 > Driveshaft
Slip Yoke - Driveline Clunk
Slip Yoke: Customer Interest Driveshaft Slip Yoke - Driveline Clunk
Article No. 83-16-23
NOISE - DRIVELINE CLUNK - AUTOMATIC TRANSMISSION/ONE-PIECE DRIVESHAFT
LIGHT TRUCKS 1981-83 E & F100-350
A driveline clunk/grunt noise at start-up and stop driving modes on some 1981-1983 light truck
vehicles, equipped with one-piece driveshafts and C4, C5, C6 or AOD automatic transmissions,
may be caused by slip yoke bind-up. To service this condition, perform the following procedure:
^ Raise the vehicle on a hoist.
^ Remove the driveshaft assembly.
NOTE: Mark the driveshaft in relation to the companion flange as it must be reinstalled in its
original position.
^ Inspect extension housing seal and replace as required.
^ Remove (and discard) slip yoke from the driveshaft.
^ Using the following chart, install a replacement slip yoke (blind spline) on the driveshaft. Grease
the slip yoke 360~ with ESA-M1C75-B multi-purpose long life lubricant.
NOTE: Complete lubricant coverage (no dry spots on spline) is necessary to ensure proper
break-in and prevention of recurring clunk.
^ Reinstall driveshaft and torque U-bolts 8-15 ft.lbs.
^ Road test.
NOTE: Vehicle should reach normal operating temperature during road test in order to properly
check transmission oil level. Add transmission fluid, as required, per Shop Manual Section 17-01.
CONSULT THE APPROPRIATE MODEL YEAR LIGHT TRUCK SHOP MANUAL WHEN
PERFORMING THE ABOVE OPERATIONS.
PART NUMBER PART NAME CLASS
E1TZ-4841-B Slip Yoke C4, 5, AOD 28T BM
E1TZ-4841-C Slip Yoke C6 BM
(except E250/350) 31T
D5UZ-4841-A Slip Yoke C6 (E250/350) 31T C
C1AZ-19590-B Lubricant - ESA-M1C75-B AG
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time
Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 4841 Code: 41
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 872218 > Nov > 87 >
Driveline - Clunk/Grunt Noise On Start Up
Slip Yoke: All Technical Service Bulletins Driveline - Clunk/Grunt Noise On Start Up
Article No. 87-22-18
^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND
STOPPING
^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING
LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87
AEROSTAR
This article is being republished in its entirety to clarify the slip yoke application chart.
ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive
modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the
transmission output shaft splines. During the same drive modes, rear suspension wrap-up
overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which
results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6
transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission;
1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2)
and 1986-87 Aerostar.
ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for
smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke
removal and installation procedures. Also, refer to the slip yoke application chart below for the
correct service part number.
PART NUMBER PART NAME CLASS
E6TZ-4841-D Slip Yoke C
E6TZ-4841-E Slip Yoke C
E6TZ-4841-F Slip Yoke C
E4TZ-4841-G Slip Yoke B
E1TZ-4841-D Slip Yoke B
D5UZ-4841-C Slip Yoke B
OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible
Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part
No. 4841 - Code: 41
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 831623 > Aug > 83 >
Driveshaft Slip Yoke - Driveline Clunk
Slip Yoke: All Technical Service Bulletins Driveshaft Slip Yoke - Driveline Clunk
Article No. 83-16-23
NOISE - DRIVELINE CLUNK - AUTOMATIC TRANSMISSION/ONE-PIECE DRIVESHAFT
LIGHT TRUCKS 1981-83 E & F100-350
A driveline clunk/grunt noise at start-up and stop driving modes on some 1981-1983 light truck
vehicles, equipped with one-piece driveshafts and C4, C5, C6 or AOD automatic transmissions,
may be caused by slip yoke bind-up. To service this condition, perform the following procedure:
^ Raise the vehicle on a hoist.
^ Remove the driveshaft assembly.
NOTE: Mark the driveshaft in relation to the companion flange as it must be reinstalled in its
original position.
^ Inspect extension housing seal and replace as required.
^ Remove (and discard) slip yoke from the driveshaft.
^ Using the following chart, install a replacement slip yoke (blind spline) on the driveshaft. Grease
the slip yoke 360~ with ESA-M1C75-B multi-purpose long life lubricant.
NOTE: Complete lubricant coverage (no dry spots on spline) is necessary to ensure proper
break-in and prevention of recurring clunk.
^ Reinstall driveshaft and torque U-bolts 8-15 ft.lbs.
^ Road test.
NOTE: Vehicle should reach normal operating temperature during road test in order to properly
check transmission oil level. Add transmission fluid, as required, per Shop Manual Section 17-01.
CONSULT THE APPROPRIATE MODEL YEAR LIGHT TRUCK SHOP MANUAL WHEN
PERFORMING THE ABOVE OPERATIONS.
PART NUMBER PART NAME CLASS
E1TZ-4841-B Slip Yoke C4, 5, AOD 28T BM
E1TZ-4841-C Slip Yoke C6 BM
(except E250/350) 31T
D5UZ-4841-A Slip Yoke C6 (E250/350) 31T C
C1AZ-19590-B Lubricant - ESA-M1C75-B AG
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time
Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 4841 Code: 41
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation
Universal Joint: Description and Operation
Fig. 3 Cross & roller type universal joints
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation > Page 2378
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool
Universal Joint: Service and Repair Servicing Using Universal Joint Replacement Tool
Fig. 7 Removing bearing caps using tool & adapter
Fig. 8 Removing bearing cap by holding cap in vise & striking center yoke with hammer
Disassembly
1. Place driveshaft in a vise using care to avoid damaging it.
2. Remove bearing retaining snap rings. Some universal joints use injected nylon retainers in place
of snap rings. During servicing, the snap rings supplied with the replacement universal joint
assembly must be used.
3. Position tool on shaft and press bearing out of yoke, Fig. 7. If bearing cannot be pressed all the
way out, remove it using vise grips or channel lock pliers or position driveshaft as shown and strike
center yoke with hammer, Fig. 8. Mark yoke and shaft to make sure they will be reassembled in
their same relative positions.
4. Reposition tool so that it presses on the spider in order to press other bearing from opposite side
of flange.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool >
Page 2381
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool >
Page 2382
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool >
Page 2383
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications
Flywheel: Specifications
Flywheel To Crankshaft Bolts 75-85 ft.lb
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks
From Breather Vent
Case: Customer Interest M/T Vent - T19, Oil Leaks From Breather Vent
Article No. 83-6-25
TRANSMISSION - MANUAL - WARNER T19 - OIL LEAKS OUT VENT - VEHICLES OVER 8500
GVW
LIGHT TRUCKS 1983 F-250/350, 1982-83 E-350 STRIPPED CHASSIS (WALK-IN VAN)
To prevent transmission gear lubricant from spouting out the primary breather vent of vehicles
equipped with Warner Gear T19 4-Speed manual transmission, relocate the vent. Referring to Section 16-24, pages 16-24-1, 16-24-3, and 16-24-10, remove the gear shift lever
assembly, boot, floor pan cover, weather pad, and gear shift housing from the transmission
assembly.
- Cover the transmission with a suitable cover (cloth, paper, etc.) to prevent accidental
contamination of the transmission gear lubricant.
- Unscrew the cap retaining the shift lever assembly in the top of the gear shift housing and remove
the shift lever assembly from the housing.
FIGURE 28
- Wipe all the grease off the shift lever lower ball and from the shift lever ball seat of the shift
housing (see Sections A and B of Figure 28).
- Remove and clean all traces of gasket material (RTV) from mounting surfaces of the shift housing
and transmission case. Remove all sealer from cover bolts.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks
From Breather Vent > Page 2396
FIGURE 27
- Remove the primary breather vent from the rear top of the shift housing (Figure 27) and press
plug, part number 353096-S into the old breather hole.
- Referring to Figure 27, locate and drill a 3/8 inch diameter hole, 1-1/4 inch forward and 3/4 inch
inboard of the centerline of the left rear shift housing attaching bolt hole.
- Press a new breather assembly, part number 01A-7034, into the new 3/8 inch diameter hole in
the shift housing.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks
From Breather Vent > Page 2397
FIGURE 28
- Apply a light coating of ESA-M1C75B lubricant to the shift lever lower ball and to the lever ball
seat in the shift housing (see Sections A and B of Figure 28).
- Apply a 1/8 bead of RTV gasket compound, part number ESB-M4G195A, to the center section
and inboard of each bolt hole of the mounting flange (see Section B of Figure 28) of the shift
housing.
- Apply ESG-M4G194A Thread Sealer to the threads of the six shift housing-to-transmission
attaching
bolt and lockwasher assemblies and secure the shift housing to transmission case. Tighten all bolts
to 25-35 lbs.ft. torque. Position the shift lever assembly to the shift housing and install as shown in Section A of Figure 28.
Torque the retaining cap to 8-15 lbs.ft. until the gasket is clamped securely.
- Connect the back-up light wire to the back-up light switch on shift housing.
- Install weather pad, floor pan cover, and floor mat or carpet as outlined in Section 16-24 of 1983
Light Truck Shop Manual.
- Check gear lubricant level in the transmission, add additional ESP-M2C83-C gear lubricant if
necessary to fill plug opening.
PART NUMBER PART NAME CLASS
01A-7034 Vent C
353096-S Plug S
C1AZ-19590-B Lubricant AG
D6AZ-19562-A RTV Gasket A
D8AZ-19554-A Thread Sealer AM
D8DZ-19C547-A Lubricant BG
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > Customer Interest for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks
From Breather Vent > Page 2398
OPERATION: M TIME:
"Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 7034
Code: 77
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 83625 > Mar > 83 > M/T Vent - T19,
Oil Leaks From Breather Vent
Case: All Technical Service Bulletins M/T Vent - T19, Oil Leaks From Breather Vent
Article No. 83-6-25
TRANSMISSION - MANUAL - WARNER T19 - OIL LEAKS OUT VENT - VEHICLES OVER 8500
GVW
LIGHT TRUCKS 1983 F-250/350, 1982-83 E-350 STRIPPED CHASSIS (WALK-IN VAN)
To prevent transmission gear lubricant from spouting out the primary breather vent of vehicles
equipped with Warner Gear T19 4-Speed manual transmission, relocate the vent. Referring to Section 16-24, pages 16-24-1, 16-24-3, and 16-24-10, remove the gear shift lever
assembly, boot, floor pan cover, weather pad, and gear shift housing from the transmission
assembly.
- Cover the transmission with a suitable cover (cloth, paper, etc.) to prevent accidental
contamination of the transmission gear lubricant.
- Unscrew the cap retaining the shift lever assembly in the top of the gear shift housing and remove
the shift lever assembly from the housing.
FIGURE 28
- Wipe all the grease off the shift lever lower ball and from the shift lever ball seat of the shift
housing (see Sections A and B of Figure 28).
- Remove and clean all traces of gasket material (RTV) from mounting surfaces of the shift housing
and transmission case. Remove all sealer from cover bolts.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 83625 > Mar > 83 > M/T Vent - T19,
Oil Leaks From Breather Vent > Page 2404
FIGURE 27
- Remove the primary breather vent from the rear top of the shift housing (Figure 27) and press
plug, part number 353096-S into the old breather hole.
- Referring to Figure 27, locate and drill a 3/8 inch diameter hole, 1-1/4 inch forward and 3/4 inch
inboard of the centerline of the left rear shift housing attaching bolt hole.
- Press a new breather assembly, part number 01A-7034, into the new 3/8 inch diameter hole in
the shift housing.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 83625 > Mar > 83 > M/T Vent - T19,
Oil Leaks From Breather Vent > Page 2405
FIGURE 28
- Apply a light coating of ESA-M1C75B lubricant to the shift lever lower ball and to the lever ball
seat in the shift housing (see Sections A and B of Figure 28).
- Apply a 1/8 bead of RTV gasket compound, part number ESB-M4G195A, to the center section
and inboard of each bolt hole of the mounting flange (see Section B of Figure 28) of the shift
housing.
- Apply ESG-M4G194A Thread Sealer to the threads of the six shift housing-to-transmission
attaching
bolt and lockwasher assemblies and secure the shift housing to transmission case. Tighten all bolts
to 25-35 lbs.ft. torque. Position the shift lever assembly to the shift housing and install as shown in Section A of Figure 28.
Torque the retaining cap to 8-15 lbs.ft. until the gasket is clamped securely.
- Connect the back-up light wire to the back-up light switch on shift housing.
- Install weather pad, floor pan cover, and floor mat or carpet as outlined in Section 16-24 of 1983
Light Truck Shop Manual.
- Check gear lubricant level in the transmission, add additional ESP-M2C83-C gear lubricant if
necessary to fill plug opening.
PART NUMBER PART NAME CLASS
01A-7034 Vent C
353096-S Plug S
C1AZ-19590-B Lubricant AG
D6AZ-19562-A RTV Gasket A
D8AZ-19554-A Thread Sealer AM
D8DZ-19C547-A Lubricant BG
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 83625 > Mar > 83 > M/T Vent - T19,
Oil Leaks From Breather Vent > Page 2406
OPERATION: M TIME:
"Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 7034
Code: 77
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage
Fluid - M/T: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2411
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2412
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2413
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > Page 2414
Fluid - M/T: Specifications
TYPE 80W EP
CAPACITY, Refill: 3-speed 3.5 pt (US)
4-speed ex. OD 7.0 pt (US)
W/OD 4.5 pt (US)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 831917 > Sep > 83 > Shift Lever Knob Pulls Off
Shifter M/T: Customer Interest Shift Lever Knob - Pulls Off
Article No. 83-19-17
TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER
LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS
Figure 17
Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is
out of specification. The following procedure is to identify the cause and to service the condition
(See Figure 17).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 831917 > Sep > 83 > Shift Lever Knob Pulls Off > Page 2423
1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert
from the shift ball. Knock the ball off the lever with a block of wood and a hammer.
2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken
or missing pieces are noted. (Retain the plastic shift pattern insert).
3. On T-19 transmission inspect the knurled end of the
shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter
should be between 37/64" and 19/32" in diameter. 4.
If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever
should be replaced with a new one with good knurls. Also install a new shift ball with the new lever.
Figure 17
5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using
the original shift lever and shift ball insert.
NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or
suitable hand grinder, file or grind a radius
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Technical Service Bulletins > Customer Interest for Shifter M/T: > 831917 > Sep > 83 > Shift Lever Knob Pulls Off > Page 2424
or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the
lever and (Figure 17, View A) to aid installation.
6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball
onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the
beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern
insert. NOTE:
Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View
A) below the knurled section of the shift lever assembly.
PART NUMBER PART NAME CLASS
E2TZ-7213-B Shift Ball B
E2TZ-7210-D Shift Lever T-18 R
E3TZ-7210-N Shift Lever T-19 C
E2TZ-7210-C Shift Lever NPG435 B
E2TZ-7210-L Shift Lever SROD R
E2TZ-7210-E Shift Lever M4OD R
E3TZ-7210-A Shift Lever TK 4 spd. C
E4TZ-7210-C Shift Lever TK 5 spd.* C
E2TZ-7210-B Shift Lever NP208/W1345 C
E3TZ-7210-K Shift Lever W-1350 C
* - Shift lever assembly includes shift tower.
OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time
Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210
Code:
01 or 16 as applicable.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 831917 > Sep > 83 > Shift
Lever Knob - Pulls Off
Shifter M/T: All Technical Service Bulletins Shift Lever Knob - Pulls Off
Article No. 83-19-17
TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER
LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS
Figure 17
Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is
out of specification. The following procedure is to identify the cause and to service the condition
(See Figure 17).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 831917 > Sep > 83 > Shift
Lever Knob - Pulls Off > Page 2430
1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert
from the shift ball. Knock the ball off the lever with a block of wood and a hammer.
2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken
or missing pieces are noted. (Retain the plastic shift pattern insert).
3. On T-19 transmission inspect the knurled end of the
shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter
should be between 37/64" and 19/32" in diameter. 4.
If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever
should be replaced with a new one with good knurls. Also install a new shift ball with the new lever.
Figure 17
5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using
the original shift lever and shift ball insert.
NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or
suitable hand grinder, file or grind a radius
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter M/T: > 831917 > Sep > 83 > Shift
Lever Knob - Pulls Off > Page 2431
or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the
lever and (Figure 17, View A) to aid installation.
6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball
onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the
beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern
insert. NOTE:
Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View
A) below the knurled section of the shift lever assembly.
PART NUMBER PART NAME CLASS
E2TZ-7213-B Shift Ball B
E2TZ-7210-D Shift Lever T-18 R
E3TZ-7210-N Shift Lever T-19 C
E2TZ-7210-C Shift Lever NPG435 B
E2TZ-7210-L Shift Lever SROD R
E2TZ-7210-E Shift Lever M4OD R
E3TZ-7210-A Shift Lever TK 4 spd. C
E4TZ-7210-C Shift Lever TK 5 spd.* C
E2TZ-7210-B Shift Lever NP208/W1345 C
E3TZ-7210-K Shift Lever W-1350 C
* - Shift lever assembly includes shift tower.
OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time
Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210
Code:
01 or 16 as applicable.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Technical Service Bulletins > Drivetrain - Lubricant Usage
Fluid - Transfer Case: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2437
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
TYPE MERCON(R) Automatic Transmission Fluid
CAPACITY, Refill: NP208 7.0 pt (US)
Warner 1345 6.5 pt (US)
Warner 1350 Ranger 3.0 pt (US)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications > Page 2440
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information
> Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls
Off
Shifter Transfer Case: Customer Interest Shift Lever Knob - Pulls Off
Article No. 83-19-17
TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER
LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS
Figure 17
Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is
out of specification. The following procedure is to identify the cause and to service the condition
(See Figure 17).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information
> Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls
Off > Page 2449
1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert
from the shift ball. Knock the ball off the lever with a block of wood and a hammer.
2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken
or missing pieces are noted. (Retain the plastic shift pattern insert).
3. On T-19 transmission inspect the knurled end of the
shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter
should be between 37/64" and 19/32" in diameter. 4.
If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever
should be replaced with a new one with good knurls. Also install a new shift ball with the new lever.
Figure 17
5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using
the original shift lever and shift ball insert.
NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or
suitable hand grinder, file or grind a radius
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information
> Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls
Off > Page 2450
or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the
lever and (Figure 17, View A) to aid installation.
6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball
onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the
beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern
insert. NOTE:
Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View
A) below the knurled section of the shift lever assembly.
PART NUMBER PART NAME CLASS
E2TZ-7213-B Shift Ball B
E2TZ-7210-D Shift Lever T-18 R
E3TZ-7210-N Shift Lever T-19 C
E2TZ-7210-C Shift Lever NPG435 B
E2TZ-7210-L Shift Lever SROD R
E2TZ-7210-E Shift Lever M4OD R
E3TZ-7210-A Shift Lever TK 4 spd. C
E4TZ-7210-C Shift Lever TK 5 spd.* C
E2TZ-7210-B Shift Lever NP208/W1345 C
E3TZ-7210-K Shift Lever W-1350 C
* - Shift lever assembly includes shift tower.
OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time
Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210
Code:
01 or 16 as applicable.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever
Knob - Pulls Off
Shifter Transfer Case: All Technical Service Bulletins Shift Lever Knob - Pulls Off
Article No. 83-19-17
TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER
LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS
Figure 17
Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is
out of specification. The following procedure is to identify the cause and to service the condition
(See Figure 17).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever
Knob - Pulls Off > Page 2456
1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert
from the shift ball. Knock the ball off the lever with a block of wood and a hammer.
2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken
or missing pieces are noted. (Retain the plastic shift pattern insert).
3. On T-19 transmission inspect the knurled end of the
shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter
should be between 37/64" and 19/32" in diameter. 4.
If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever
should be replaced with a new one with good knurls. Also install a new shift ball with the new lever.
Figure 17
5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using
the original shift lever and shift ball insert.
NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or
suitable hand grinder, file or grind a radius
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever
Knob - Pulls Off > Page 2457
or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the
lever and (Figure 17, View A) to aid installation.
6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball
onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the
beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern
insert. NOTE:
Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View
A) below the knurled section of the shift lever assembly.
PART NUMBER PART NAME CLASS
E2TZ-7213-B Shift Ball B
E2TZ-7210-D Shift Lever T-18 R
E3TZ-7210-N Shift Lever T-19 C
E2TZ-7210-C Shift Lever NPG435 B
E2TZ-7210-L Shift Lever SROD R
E2TZ-7210-E Shift Lever M4OD R
E3TZ-7210-A Shift Lever TK 4 spd. C
E4TZ-7210-C Shift Lever TK 5 spd.* C
E2TZ-7210-B Shift Lever NP208/W1345 C
E3TZ-7210-K Shift Lever W-1350 C
* - Shift lever assembly includes shift tower.
OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time
Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210
Code:
01 or 16 as applicable.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > System Information > System
Diagnosis
Transmission Control Systems: Testing and Inspection
For Transmission Control Systems Diagnosis, go to Powertrain Management/Computers and
Control Systems/Testing and Inspection.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair
Brake Bleeding: Service and Repair
Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on
each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has
been drained from hydraulic system.
1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to
absorb escaping brake fluid.
2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at
fitting.
3. Hold pedal down and tighten fittings, then release brake pedal. Releasing brake pedal before
fittings are tightened will allow air to enter the master cylinder.
4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm.
5. Bleed rear brakes as follows:
a. Pump pedal several times, then hold pedal down firmly. b. With pedal firmly depressed, open
bleeder screw on one rear brake until pedal fades to floor, then close bleeder valve. c. Repeat
procedure until a continuous flow of brake fluid is released from bleeder valve. d. Repeat steps 5a
through 5c on other rear brake.
6. Bleed front brakes using same procedure as for rear brakes.
7. Fill master cylinder reservoirs to {1/4} inch from top of reservoirs.
8. Centralize the pressure differential control valve, if applicable, as follows:
a. Turn ignition switch to ``ACC'' or ``On'' position. b. Push brake pedal down, allowing piston to
center itself, turning off warning light. c. Turn ignition switch to ``OFF'' position.
9. Check brake operation and ensure pedal is firm, then road test vehicle.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear
Brake Caliper: Customer Interest Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2474
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2475
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2476
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2477
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2478
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2479
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2480
OASIS CODES: 301000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 86621 > Mar > 86 > Front Disc Brakes - Clunk During
Braking
Brake Caliper: Customer Interest Front Disc Brakes - Clunk During Braking
Article No. 86-6-21
BRAKES - FRONT DISC - CLUNK
LIGHT TRUCK 1980-85 E250/350, F250/350
Some 1980-85 250/350 Econoline and F Series vehicles over 6900 GVW are experiencing front
disc brake clunk during braking. This concern can be corrected by using new caliper support keys
and springs as outlined in the following procedure.
1. Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coat of
ESAM1C172-A (D7AZ-19590-A) lubricant to both surfaces, being careful not to get lubricant on
rotors or linings.
2. Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the
Light Truck Shop Manual procedures, Section 11- 10 and 11-12.
3. Discard the old caliper support key and spring and reinstall the caliper using a new service key
(D7TZ- 2B487-B) and spring (D7TZ-2B486-B).
PART NUMBER PART NAME CLASS
D7TZ-2B487-B Support Key A
D7TZ-2B486-B Spring A
D7AZ-19590-A Lubricant A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP2487A86 TIME:
0.6 Hr. DLR. CODING: Basic Part No. 2B487 - Code: 33
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear
Brake Caliper: All Technical Service Bulletins Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2490
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2491
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2492
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2493
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2494
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2495
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2496
OASIS CODES: 301000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 86621 > Mar > 86 > Front Disc Brakes Clunk During Braking
Brake Caliper: All Technical Service Bulletins Front Disc Brakes - Clunk During Braking
Article No. 86-6-21
BRAKES - FRONT DISC - CLUNK
LIGHT TRUCK 1980-85 E250/350, F250/350
Some 1980-85 250/350 Econoline and F Series vehicles over 6900 GVW are experiencing front
disc brake clunk during braking. This concern can be corrected by using new caliper support keys
and springs as outlined in the following procedure.
1. Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coat of
ESAM1C172-A (D7AZ-19590-A) lubricant to both surfaces, being careful not to get lubricant on
rotors or linings.
2. Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the
Light Truck Shop Manual procedures, Section 11- 10 and 11-12.
3. Discard the old caliper support key and spring and reinstall the caliper using a new service key
(D7TZ- 2B487-B) and spring (D7TZ-2B486-B).
PART NUMBER PART NAME CLASS
D7TZ-2B487-B Support Key A
D7TZ-2B486-B Spring A
D7AZ-19590-A Lubricant A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP2487A86 TIME:
0.6 Hr. DLR. CODING: Basic Part No. 2B487 - Code: 33
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper Removal
Brake Caliper: Service and Repair Caliper Removal
Fig. 1 Bottoming caliper piston in cylinder bore
1. Remove a portion of brake fluid from master cylinder disc brake reservoir.
2. Raise and support vehicle and remove wheel and tire assembly.
3. Install eight inch C-clamp on caliper, Fig. 1, and tighten clamp to bottom piston in cylinder bore,
then remove clamp. Do not use screwdriver or other edged tool to pry piston from rotor.
4. Remove key retaining screw, then using hammer and drift, drive out caliper support key and
spring.
5. Remove caliper by pushing it downward against spindle assembly and rotating upper end
upward and out of spindle assembly.
6. Disconnect hydraulic line from caliper.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper Removal > Page 2503
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper Removal > Page 2504
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Caliper Removal > Page 2505
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear
Brake Pad: Customer Interest Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2514
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2515
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2516
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2517
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2518
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2519
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2520
OASIS CODES: 301000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 86813 > Apr > 86 > Front Disc Brakes - Squealing Noise
Brake Pad: Customer Interest Front Disc Brakes - Squealing Noise
Article No. 86-8-13
BRAKES - FRONT DISC - SQUEAL
LIGHT TRUCK 1980-86 E100/350, F100/350, BRONCO
If the subject vehicles are experiencing a brake squeal concern, they should be serviced by
installing insulator pads. Information in TSB 85-3-10 should not be used, this new service action
supersedes the previous article with updated information.
The following procedures and precautions should be observed when servicing front brake squeal
concerns.
^ Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coating of
ESAM1C172-A(D7AZ-19590-A) lubricant to both surfaces. Be careful not to get lube on rotors or
linings. Wipe any excess lube off after assembly. Visually inspect rotors for any obvious damage or
scoring.
^ Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the
procedures included in the Light Truck Shop Manual, Sections 11-10 and 11-12.
NOTE: The disc brake caliper and pads must be removed from the spindle prior to adjusting the
front wheel bearings.
^ Clean lining and rotor surfaces. Remove any uneven glaze buildup on lining and rotor braking
surfaces by sanding with medium to fine sandpaper or emery cloth. Uniform rotor sanding can be
accomplished by holding the paper against the rotor braking surface while manually turning the
rotor.
^ Remove any loose insulator material from the pad backing plates with sandpaper or an
appropriate solvent.
This procedure applies only to the following models: 1980-86 E100/150, F100/150, Bronco, F250
4x2 under 6900 lbs. GVW (single piston calipers).
^ Install the service insulator (E1TZ-2B321-A) to the backing plate of the OUTBOARD pad and
lining assembly (both L.H. and R.H. brake). Bond the insulator to the back side of the brake pad
assembly with ESA-M1C140-A1 (D7AZ-19554-C) adhesive. Apply adhesive to the light color side
of each insulator. Assure that insulator is centered on backing plate and that directions for applying
adhesive are followed.
This procedure is for 1980-86 F250 4x2 over 6900 lbs. GVW, F250 4x4, F350, E250/350 (dual
piston calipers).
^ Install the service insulator (E1TZ-2B321-B) to the back side of the INBOARD pad and lining
assembly (both L.H. and R.H. brake). Bond the insulator to the backing plate and lining assembly
using the previously listed procedure.
^ Install the service shim (E6TZ-2B321-A) to the back side of the outboard pad and lining assembly
(both L.H. and R.H. brake) by clipping the shim over the straight edge of the backing plate. Be sure
the shim is fully seated and centered on the straight edge of the backing plate.
NOTE: For dual piston caliper application only.
^ Reinstall caliper to the spindle assembly.
NOTE: DO NOT replace linings unless required for wear or additional concerns (Shop Manual,
Section 12-24).
PART NUMBER PART NAME CLASS
E1TZ-2B321-A Insulator BM
E1TZ-2B321-B Insulator BM
E6TZ-2B321-A Shim B
D7AZ-19590-A Lubricant A
D7AZ-19554-C Adhesive AM
OTHER APPLICABLE ARTICLES: Supersedes 85-3-10 WARRANTY STATUS: Reimbursable
within the provisions of the Warranty and Policy Manual. OPERATION: SP2321A86A - 1980-85
TIME:
1.1 Hrs.
OPERATION: SP2321A86B - 1986 TIME:
1.0 Hr. DLR. CODING: Basic Part No. 2001 - Code: 56
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear
Brake Pad: Customer Interest Brakes (Rear) - Accelerated Wear
Articles No. 84-16-28
BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES
LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO
This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E &
F-100/150 & Bronco vehicles that have 11" diameter rear brakes.
Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban
delivery/service operations may experience accelerated rear brake wear. A service
kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the
vehicle exhibits any of the following conditions:
^ Side to side imbalance in rear braking effectiveness.
^ Side to side imbalance in rear brake lining wear.
^ Excessive heat ("blued" shoes and/or drums).
The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a
proportioning valve. These parts must be installed per the appropriate shop manual installation
procedure.
NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake
backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before
installing the service kit (E0UZ-2C178-A).
PART NUMBER PART NAME CLASS
E0UZ-2C178-A Brake Service Kit C
Front/Rear Services
OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION:
SP2178A83 TIME:
2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 83519 > Mar > 83 > Rear Brakes - Abnormal Rear Brake
Wear
Brake Pad: Customer Interest Rear Brakes - Abnormal Rear Brake Wear
Article No. 83-5-19
BRAKE - REAR - WEAR - AMBULANCE VEHICLES, E & F 250/350 OVER 8500 GVW
LIGHT TRUCKS 1976-82 E-350
Ambulance vehicles that experience unusual rear brake wear should be updated to the 1982
ambulance brake package level using the following procedure. (1976 through 1982 vehicles may
be affected).
Technical Service Bulletin 80-21, Article 80-21-15, dated October 24, 1980 addressed procedures
that helped to minimize rear brake wear. This method is still recommended. Under certain
circumstances of severe customer usage involving extremely high loads and frequent stopping
(i.e., emergency vehicles), the following procedure is also recommended.
Perform operation described in Technical Service Bulletin 80-21, Article 80-21-15 and update the
front and rear brake systems as follows:
^ Install new front disc brake pad and lining assemblies, D9TZ-2001-A.
NOTE: Service or replace disc brake rotor assemblies, if required.
^ 12 x 3 Inch Brakes - Install new rear brake shoe and lining assemblies (Part Number
D7TZ-2200-A).
Color Code: Secondary 1 green/ 1 red, primary 1 pink/1 yellow right and lefthand.
^ 12 x 2.5 Inch Brakes - Install new rear brake shoe and lining assemblies, (Part Number
D7TZ-2200-B). Color Code: Secondary 1 white/1 white primary 1 red/ 1 yellow right and lefthand.
^ Inspect rear brake wheel cylinder; checking cylinder size. Replace 1-1/16 inch diameter R.H. and
L.H. wheel cylinder assemblies with 1 inch diameter R.H. and L.H. wheel cylinder assemblies
(D6TZ-2261- A/R.H. and D6TZ-2262-A/L.H.).
^ Replace upper brake shoe retracting spring (green) C6TZ-2296-A with C6TZ-2035-A (red).
^ Replace valve with D9TA-2B524-AA.
^ Bleed hydraulic system as outlined in the 1977-1983 Light Truck Shop Manual.
^ Lining Conditioning Procedure
Owners should be informed that unnecessary brake wear can be avoided only if the following
burnish procedure is performed prior to putting an emergency vehicle into service: ^
100 moderate snub stops from 40 to 20 mph.
^ 10 stops from 60 to 0 mph at 1/2 mile intervals at maximum deceleration without wheel lock-up.
NOTE: These heavy duty shoe and lining service kits must be used in applications specified in the
Ford Light Truck Parts Catalog or the Ford Technical Service Bulletin specifying mandatory front
linings, rear wheel cylinders and installation procedures for vehicles not originally equipped with
these linings.
PART NUMBER PART NAME CLASS
D9TZ-2001-A Front Shoe & Lining Kit B
D7TZ-2200-A Heavy Duty Lining Kit 12" x 3" BM
D7TZ-2200-B Heavy Duty Lining Kit 12" x 2.5" B
D6TZ-2261-A Wheel Cylinder 1.0" RH A
D6TZ-2262-A Wheel Cylinder 1.0" LH A
C6TZ-2035-A Retracting Spring Rear Brake A
D9TZ-2B257-A Valve C
OTHER APPLICABLE ARTICLES: 81-15-19, 80-21-15
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time.
DLR. CODING: Basic Part No. R2007 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear
Brake Pad: All Technical Service Bulletins Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2538
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2539
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2540
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2541
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2542
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2543
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 2544
OASIS CODES: 301000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 86813 > Apr > 86 > Front Disc Brakes Squealing Noise
Brake Pad: All Technical Service Bulletins Front Disc Brakes - Squealing Noise
Article No. 86-8-13
BRAKES - FRONT DISC - SQUEAL
LIGHT TRUCK 1980-86 E100/350, F100/350, BRONCO
If the subject vehicles are experiencing a brake squeal concern, they should be serviced by
installing insulator pads. Information in TSB 85-3-10 should not be used, this new service action
supersedes the previous article with updated information.
The following procedures and precautions should be observed when servicing front brake squeal
concerns.
^ Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coating of
ESAM1C172-A(D7AZ-19590-A) lubricant to both surfaces. Be careful not to get lube on rotors or
linings. Wipe any excess lube off after assembly. Visually inspect rotors for any obvious damage or
scoring.
^ Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the
procedures included in the Light Truck Shop Manual, Sections 11-10 and 11-12.
NOTE: The disc brake caliper and pads must be removed from the spindle prior to adjusting the
front wheel bearings.
^ Clean lining and rotor surfaces. Remove any uneven glaze buildup on lining and rotor braking
surfaces by sanding with medium to fine sandpaper or emery cloth. Uniform rotor sanding can be
accomplished by holding the paper against the rotor braking surface while manually turning the
rotor.
^ Remove any loose insulator material from the pad backing plates with sandpaper or an
appropriate solvent.
This procedure applies only to the following models: 1980-86 E100/150, F100/150, Bronco, F250
4x2 under 6900 lbs. GVW (single piston calipers).
^ Install the service insulator (E1TZ-2B321-A) to the backing plate of the OUTBOARD pad and
lining assembly (both L.H. and R.H. brake). Bond the insulator to the back side of the brake pad
assembly with ESA-M1C140-A1 (D7AZ-19554-C) adhesive. Apply adhesive to the light color side
of each insulator. Assure that insulator is centered on backing plate and that directions for applying
adhesive are followed.
This procedure is for 1980-86 F250 4x2 over 6900 lbs. GVW, F250 4x4, F350, E250/350 (dual
piston calipers).
^ Install the service insulator (E1TZ-2B321-B) to the back side of the INBOARD pad and lining
assembly (both L.H. and R.H. brake). Bond the insulator to the backing plate and lining assembly
using the previously listed procedure.
^ Install the service shim (E6TZ-2B321-A) to the back side of the outboard pad and lining assembly
(both L.H. and R.H. brake) by clipping the shim over the straight edge of the backing plate. Be sure
the shim is fully seated and centered on the straight edge of the backing plate.
NOTE: For dual piston caliper application only.
^ Reinstall caliper to the spindle assembly.
NOTE: DO NOT replace linings unless required for wear or additional concerns (Shop Manual,
Section 12-24).
PART NUMBER PART NAME CLASS
E1TZ-2B321-A Insulator BM
E1TZ-2B321-B Insulator BM
E6TZ-2B321-A Shim B
D7AZ-19590-A Lubricant A
D7AZ-19554-C Adhesive AM
OTHER APPLICABLE ARTICLES: Supersedes 85-3-10 WARRANTY STATUS: Reimbursable
within the provisions of the Warranty and Policy Manual. OPERATION: SP2321A86A - 1980-85
TIME:
1.1 Hrs.
OPERATION: SP2321A86B - 1986 TIME:
1.0 Hr. DLR. CODING: Basic Part No. 2001 - Code: 56
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 841628 > Jul > 84 > Brakes (Rear) Accelerated Wear
Brake Pad: All Technical Service Bulletins Brakes (Rear) - Accelerated Wear
Articles No. 84-16-28
BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES
LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO
This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E &
F-100/150 & Bronco vehicles that have 11" diameter rear brakes.
Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban
delivery/service operations may experience accelerated rear brake wear. A service
kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the
vehicle exhibits any of the following conditions:
^ Side to side imbalance in rear braking effectiveness.
^ Side to side imbalance in rear brake lining wear.
^ Excessive heat ("blued" shoes and/or drums).
The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a
proportioning valve. These parts must be installed per the appropriate shop manual installation
procedure.
NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake
backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before
installing the service kit (E0UZ-2C178-A).
PART NUMBER PART NAME CLASS
E0UZ-2C178-A Brake Service Kit C
Front/Rear Services
OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION:
SP2178A83 TIME:
2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 83519 > Mar > 83 > Rear Brakes - Abnormal
Rear Brake Wear
Brake Pad: All Technical Service Bulletins Rear Brakes - Abnormal Rear Brake Wear
Article No. 83-5-19
BRAKE - REAR - WEAR - AMBULANCE VEHICLES, E & F 250/350 OVER 8500 GVW
LIGHT TRUCKS 1976-82 E-350
Ambulance vehicles that experience unusual rear brake wear should be updated to the 1982
ambulance brake package level using the following procedure. (1976 through 1982 vehicles may
be affected).
Technical Service Bulletin 80-21, Article 80-21-15, dated October 24, 1980 addressed procedures
that helped to minimize rear brake wear. This method is still recommended. Under certain
circumstances of severe customer usage involving extremely high loads and frequent stopping
(i.e., emergency vehicles), the following procedure is also recommended.
Perform operation described in Technical Service Bulletin 80-21, Article 80-21-15 and update the
front and rear brake systems as follows:
^ Install new front disc brake pad and lining assemblies, D9TZ-2001-A.
NOTE: Service or replace disc brake rotor assemblies, if required.
^ 12 x 3 Inch Brakes - Install new rear brake shoe and lining assemblies (Part Number
D7TZ-2200-A).
Color Code: Secondary 1 green/ 1 red, primary 1 pink/1 yellow right and lefthand.
^ 12 x 2.5 Inch Brakes - Install new rear brake shoe and lining assemblies, (Part Number
D7TZ-2200-B). Color Code: Secondary 1 white/1 white primary 1 red/ 1 yellow right and lefthand.
^ Inspect rear brake wheel cylinder; checking cylinder size. Replace 1-1/16 inch diameter R.H. and
L.H. wheel cylinder assemblies with 1 inch diameter R.H. and L.H. wheel cylinder assemblies
(D6TZ-2261- A/R.H. and D6TZ-2262-A/L.H.).
^ Replace upper brake shoe retracting spring (green) C6TZ-2296-A with C6TZ-2035-A (red).
^ Replace valve with D9TA-2B524-AA.
^ Bleed hydraulic system as outlined in the 1977-1983 Light Truck Shop Manual.
^ Lining Conditioning Procedure
Owners should be informed that unnecessary brake wear can be avoided only if the following
burnish procedure is performed prior to putting an emergency vehicle into service: ^
100 moderate snub stops from 40 to 20 mph.
^ 10 stops from 60 to 0 mph at 1/2 mile intervals at maximum deceleration without wheel lock-up.
NOTE: These heavy duty shoe and lining service kits must be used in applications specified in the
Ford Light Truck Parts Catalog or the Ford Technical Service Bulletin specifying mandatory front
linings, rear wheel cylinders and installation procedures for vehicles not originally equipped with
these linings.
PART NUMBER PART NAME CLASS
D9TZ-2001-A Front Shoe & Lining Kit B
D7TZ-2200-A Heavy Duty Lining Kit 12" x 3" BM
D7TZ-2200-B Heavy Duty Lining Kit 12" x 2.5" B
D6TZ-2261-A Wheel Cylinder 1.0" RH A
D6TZ-2262-A Wheel Cylinder 1.0" LH A
C6TZ-2035-A Retracting Spring Rear Brake A
D9TZ-2B257-A Valve C
OTHER APPLICABLE ARTICLES: 81-15-19, 80-21-15
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time.
DLR. CODING: Basic Part No. R2007 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Page 2557
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > Customer Interest: > 872414 > Dec > 87 > Brakes - Shudder and Vibration On Application
Brake Rotor/Disc: Customer Interest Brakes - Shudder and Vibration On Application
Article No. 87-24-14
BRAKE - ROTORS - SHUDDER AND VIBRATION DURING APPLICATION - CRACKED ROTOR
ASSEMBLY
VIBRATION AND SHUDDER - DURING BRAKE APPLICATION - CRACKED ROTOR
LIGHT TRUCK: 1980-87 E-250/350, F-250/350
ISSUE: Shudder and vibration during brake application may be caused by cracks in the braking
surface of the front disc brake rotors. Units that may be affected are 1980-87 E-250/350 and 4 x 2
F-250/350 vehicles with single rear wheels (SRW) and 1980-87 E-350 and 4 x 2 F-350 vehicles
with dual rear wheels (DRW).
ACTION: To correct this, install new design heavy-duty brake rotors. Refer to the Application Chart
below for the correct service part numbers.
PART NUMBER PART NAME CLASS
E0TZ-1102-J Disc Brake Rotor B
E0TZ-1102-K Disc Brake Rotor B
E0TZ-1102-L Disc Brake Rotor B
E7TZ-1102-C Disc Brake Rotor B
E7TZ-1102-D Disc Brake Rotor B
OTHER APPLICABLE ARTICLES: Supersedes 87-16-16 WARRANTY STATUS: Eligible Under
Basic Warranty Coverage OPERATION: SP872414A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 1102 - Code: 01
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 831112S > Sep > 84 > Fuel System Stalls/No Start/Hesitation/ Stumble
Fuel Pump Inertia Switch: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/
Stumble
Article No. 83-11-12-S
STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES
OVER 8500 LBS. GVW
LIGHT TRUCKS 1980/82 E250/350, F250/350
The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to
E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article
is being reprinted showing the correct part numbers.
NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to
use TSB 82-14-21 to order service parts.
Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient
temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A
modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel
pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return
system, along with related fuel lines and electrical wiring and devices.
Before this modification is considered, other factors that could result in the same symptoms should
be evaluated. Some of these include:
^ Plugged fuel filter at carburetor or tank.
^ Restricted fuel line.
^ Contaminated or low quality fuel.
^ Malfunctioning fuel pump or carburetor.
If it is determined that the above factors have not caused the customer concern then the
appropriate modification kit should be used to change the fuel system.
Hardware Required:
Components required to modify the vehicle differ with vehicle series, engine model and type of fuel
tank. These have been packaged into 13 different kits. The chart that follows describes the specific
kits that are required for the various vehicle configurations.
Continued on next page
TANK ENGINE (CID) KITS REQUIRED
F-Series Single (Midship) 351M/400 A, F, H
Single (Plastic Aft Axle) 351M/400 F, C, L
Single (Metal Aft Axle) 351M/400 B, F, L
Dual (Steel Aft Axle) 351M/400 A, B, F, I
Dual (Plastic Aft Axle) 351M/400 A, C, F, I
E-Series Single (Aft Axle) 351M/400 D, F, J
Dual 351M/400 D, E, F, K
E-Series Single (Aft Axle) 7.5L 460 D, G, J
Dual 7.5L 460 D, E, G, K
KIT SERVICE PART NO. DESCRIPTION CLASS
A E2TZ-9350-D Fuel Pump/Sender Kit CG
B E2TZ-9350-F Fuel Pump/Sender Kit CG
C E2TZ-9350-C Fuel Pump/Sender Kit CG
D E0UZ-9350-D Fuel Pump/Sender Kit CG
E E0UZ-9350-C Fuel Pump/Sender Kit CG
F E0TZ-9B328-A Vapor Separator Kit CG
G E0TZ-9B328-B Vapor Separator Kit CG
H E2TZ-9A350-H Fuel Line/Electrical Kit CG
I E2TZ-9A350-F Fuel Line/Electrical Kit CG
J E2UZ-9A350-F Fuel Line/Electrical Kit CG
K E2UZ-9A350-D Fuel Line/Electrical Kit CG
L E2TZ-9350-G Fuel Line/Electrical Kit CG
Select the appropriate kit required; the detailed installation instructions will be supplied with each
kit.
OTHER APPLICABLE ARTICLES: 83-11-12
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 831112S > Sep > 84 > Fuel System Stalls/No Start/Hesitation/ Stumble > Page 2576
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 831112S > Sep > 84 > Fuel System Stalls/No Start/Hesitation/ Stumble > Page 2582
ARTICLES SUPERSEDED: 82-14-21; 83-11-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
DLR. CODING: Basic Part No. 9237 Code: H6
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > Page 2583
Brake Rotor/Disc: Specifications
Front Nominal Thickness 1.25 in
Minimum Thickness 1.18 in
Thickness Variation (Parallelism)
Note: Integral hub & rotor, .0007 inch; separate hub &
rotor, .0010 inch.
Run Out (TIR)
Note: Integral hub & rotor, .0030 inch; separate hub &
rotor, .0010 inch.
Finish 15-80 micro-in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications
Brake Drum: Specifications
Rear Inside Diameter 12.0 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Installation
Brake Drum: Service and Repair Installation
1. Clean ledge pads on backing plate, sanding lightly to bare metal.
2. Apply suitable lubricant to retracting and hold-down spring contacts on brake shoes and backing
plate.
3. Apply suitable lubricant to threads and socket end of adjusting screw.
4. Install upper retracting spring on primary and secondary shoes and position shoe assembly on
backing plate with wheel cylinder pushrods in shoe slots.
5. Install brake shoe hold-down springs.
6. Install brake shoe adjustment screw assembly with the slot in the head of adjustment screw
facing primary shoe, lower retracting spring, adjusting lever spring, and adjusting lever assembly,
and connect adjusting cable to adjusting lever. Socket end of each adjusting screw is stamped ``R''
or ``L'' to indicate use on right or left side of vehicle. Adjusting pivot nuts can be identified by
number of lines machined around body of nut. Two lines indicate righthand nut and one line
indicates lefthand nut.
7. Position cable in cable guide and install cable anchor fitting on the anchor pin.
8. Install parking brake assembly in anchor pin and secure with retaining nut behind backing plate.
9. On vehicles with full-floating axles, install brake drums as follows:
a. Place brake drum on hub and install attaching screws, bolts, or bolts and nuts. b. Place hub and
drum as an assembly on axle and start adjusting nut. c. Adjust wheel bearing nut and install wheel
bearing lock washer and lock nut. See REAR AXLE for procedure. d. Install new gasket and the
bolts and lock washers. e. Install wheel and tire assembly. f.
Adjust brakes. Refer to individual truck chapter for correct adjustment procedure.
10. On vehicles with semi-floating axles, install brake drums as follows:
a. Adjust brakes. Refer to individual truck chapter for correct adjustment procedure. b. Install drum.
c. Install brake drum retaining nuts and tighten securely. d. Install wheel on axle shaft flange studs
against drum, and tighten retaining nuts.
11. If any hydraulic connections have been opened, perform system brake bleeding procedures.
12. Check master cylinder fluid level, filling as necessary.
13. Check brake pedal for proper feel and return.
14. Lower vehicle and road test.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Installation > Page 2590
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Customer Interest for Brake Shoe: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear
Brake Shoe: Customer Interest Brakes (Rear) - Accelerated Wear
Articles No. 84-16-28
BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES
LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO
This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E &
F-100/150 & Bronco vehicles that have 11" diameter rear brakes.
Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban
delivery/service operations may experience accelerated rear brake wear. A service
kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the
vehicle exhibits any of the following conditions:
^ Side to side imbalance in rear braking effectiveness.
^ Side to side imbalance in rear brake lining wear.
^ Excessive heat ("blued" shoes and/or drums).
The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a
proportioning valve. These parts must be installed per the appropriate shop manual installation
procedure.
NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake
backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before
installing the service kit (E0UZ-2C178-A).
PART NUMBER PART NAME CLASS
E0UZ-2C178-A Brake Service Kit C
Front/Rear Services
OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION:
SP2178A83 TIME:
2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Customer Interest for Brake Shoe: > 83519 > Mar > 83 > Rear Brakes - Abnormal Rear Brake
Wear
Brake Shoe: Customer Interest Rear Brakes - Abnormal Rear Brake Wear
Article No. 83-5-19
BRAKE - REAR - WEAR - AMBULANCE VEHICLES, E & F 250/350 OVER 8500 GVW
LIGHT TRUCKS 1976-82 E-350
Ambulance vehicles that experience unusual rear brake wear should be updated to the 1982
ambulance brake package level using the following procedure. (1976 through 1982 vehicles may
be affected).
Technical Service Bulletin 80-21, Article 80-21-15, dated October 24, 1980 addressed procedures
that helped to minimize rear brake wear. This method is still recommended. Under certain
circumstances of severe customer usage involving extremely high loads and frequent stopping
(i.e., emergency vehicles), the following procedure is also recommended.
Perform operation described in Technical Service Bulletin 80-21, Article 80-21-15 and update the
front and rear brake systems as follows:
^ Install new front disc brake pad and lining assemblies, D9TZ-2001-A.
NOTE: Service or replace disc brake rotor assemblies, if required.
^ 12 x 3 Inch Brakes - Install new rear brake shoe and lining assemblies (Part Number
D7TZ-2200-A).
Color Code: Secondary 1 green/ 1 red, primary 1 pink/1 yellow right and lefthand.
^ 12 x 2.5 Inch Brakes - Install new rear brake shoe and lining assemblies, (Part Number
D7TZ-2200-B). Color Code: Secondary 1 white/1 white primary 1 red/ 1 yellow right and lefthand.
^ Inspect rear brake wheel cylinder; checking cylinder size. Replace 1-1/16 inch diameter R.H. and
L.H. wheel cylinder assemblies with 1 inch diameter R.H. and L.H. wheel cylinder assemblies
(D6TZ-2261- A/R.H. and D6TZ-2262-A/L.H.).
^ Replace upper brake shoe retracting spring (green) C6TZ-2296-A with C6TZ-2035-A (red).
^ Replace valve with D9TA-2B524-AA.
^ Bleed hydraulic system as outlined in the 1977-1983 Light Truck Shop Manual.
^ Lining Conditioning Procedure
Owners should be informed that unnecessary brake wear can be avoided only if the following
burnish procedure is performed prior to putting an emergency vehicle into service: ^
100 moderate snub stops from 40 to 20 mph.
^ 10 stops from 60 to 0 mph at 1/2 mile intervals at maximum deceleration without wheel lock-up.
NOTE: These heavy duty shoe and lining service kits must be used in applications specified in the
Ford Light Truck Parts Catalog or the Ford Technical Service Bulletin specifying mandatory front
linings, rear wheel cylinders and installation procedures for vehicles not originally equipped with
these linings.
PART NUMBER PART NAME CLASS
D9TZ-2001-A Front Shoe & Lining Kit B
D7TZ-2200-A Heavy Duty Lining Kit 12" x 3" BM
D7TZ-2200-B Heavy Duty Lining Kit 12" x 2.5" B
D6TZ-2261-A Wheel Cylinder 1.0" RH A
D6TZ-2262-A Wheel Cylinder 1.0" LH A
C6TZ-2035-A Retracting Spring Rear Brake A
D9TZ-2B257-A Valve C
OTHER APPLICABLE ARTICLES: 81-15-19, 80-21-15
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time.
DLR. CODING: Basic Part No. R2007 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 841628 > Jul > 84 > Brakes (Rear) Accelerated Wear
Brake Shoe: All Technical Service Bulletins Brakes (Rear) - Accelerated Wear
Articles No. 84-16-28
BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES
LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO
This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E &
F-100/150 & Bronco vehicles that have 11" diameter rear brakes.
Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban
delivery/service operations may experience accelerated rear brake wear. A service
kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the
vehicle exhibits any of the following conditions:
^ Side to side imbalance in rear braking effectiveness.
^ Side to side imbalance in rear brake lining wear.
^ Excessive heat ("blued" shoes and/or drums).
The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a
proportioning valve. These parts must be installed per the appropriate shop manual installation
procedure.
NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake
backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before
installing the service kit (E0UZ-2C178-A).
PART NUMBER PART NAME CLASS
E0UZ-2C178-A Brake Service Kit C
Front/Rear Services
OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION:
SP2178A83 TIME:
2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 83519 > Mar > 83 > Rear Brakes - Abnormal
Rear Brake Wear
Brake Shoe: All Technical Service Bulletins Rear Brakes - Abnormal Rear Brake Wear
Article No. 83-5-19
BRAKE - REAR - WEAR - AMBULANCE VEHICLES, E & F 250/350 OVER 8500 GVW
LIGHT TRUCKS 1976-82 E-350
Ambulance vehicles that experience unusual rear brake wear should be updated to the 1982
ambulance brake package level using the following procedure. (1976 through 1982 vehicles may
be affected).
Technical Service Bulletin 80-21, Article 80-21-15, dated October 24, 1980 addressed procedures
that helped to minimize rear brake wear. This method is still recommended. Under certain
circumstances of severe customer usage involving extremely high loads and frequent stopping
(i.e., emergency vehicles), the following procedure is also recommended.
Perform operation described in Technical Service Bulletin 80-21, Article 80-21-15 and update the
front and rear brake systems as follows:
^ Install new front disc brake pad and lining assemblies, D9TZ-2001-A.
NOTE: Service or replace disc brake rotor assemblies, if required.
^ 12 x 3 Inch Brakes - Install new rear brake shoe and lining assemblies (Part Number
D7TZ-2200-A).
Color Code: Secondary 1 green/ 1 red, primary 1 pink/1 yellow right and lefthand.
^ 12 x 2.5 Inch Brakes - Install new rear brake shoe and lining assemblies, (Part Number
D7TZ-2200-B). Color Code: Secondary 1 white/1 white primary 1 red/ 1 yellow right and lefthand.
^ Inspect rear brake wheel cylinder; checking cylinder size. Replace 1-1/16 inch diameter R.H. and
L.H. wheel cylinder assemblies with 1 inch diameter R.H. and L.H. wheel cylinder assemblies
(D6TZ-2261- A/R.H. and D6TZ-2262-A/L.H.).
^ Replace upper brake shoe retracting spring (green) C6TZ-2296-A with C6TZ-2035-A (red).
^ Replace valve with D9TA-2B524-AA.
^ Bleed hydraulic system as outlined in the 1977-1983 Light Truck Shop Manual.
^ Lining Conditioning Procedure
Owners should be informed that unnecessary brake wear can be avoided only if the following
burnish procedure is performed prior to putting an emergency vehicle into service: ^
100 moderate snub stops from 40 to 20 mph.
^ 10 stops from 60 to 0 mph at 1/2 mile intervals at maximum deceleration without wheel lock-up.
NOTE: These heavy duty shoe and lining service kits must be used in applications specified in the
Ford Light Truck Parts Catalog or the Ford Technical Service Bulletin specifying mandatory front
linings, rear wheel cylinders and installation procedures for vehicles not originally equipped with
these linings.
PART NUMBER PART NAME CLASS
D9TZ-2001-A Front Shoe & Lining Kit B
D7TZ-2200-A Heavy Duty Lining Kit 12" x 3" BM
D7TZ-2200-B Heavy Duty Lining Kit 12" x 2.5" B
D6TZ-2261-A Wheel Cylinder 1.0" RH A
D6TZ-2262-A Wheel Cylinder 1.0" LH A
C6TZ-2035-A Retracting Spring Rear Brake A
D9TZ-2B257-A Valve C
OTHER APPLICABLE ARTICLES: 81-15-19, 80-21-15
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time.
DLR. CODING: Basic Part No. R2007 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Page 2612
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Installation
Brake Shoe: Service and Repair Installation
1. Clean ledge pads on backing plate, sanding lightly to bare metal.
2. Apply suitable lubricant to retracting and hold-down spring contacts on brake shoes and backing
plate.
3. Apply suitable lubricant to threads and socket end of adjusting screw.
4. Install upper retracting spring on primary and secondary shoes and position shoe assembly on
backing plate with wheel cylinder pushrods in shoe slots.
5. Install brake shoe hold-down springs.
6. Install brake shoe adjustment screw assembly with the slot in the head of adjustment screw
facing primary shoe, lower retracting spring, adjusting lever spring, and adjusting lever assembly,
and connect adjusting cable to adjusting lever. Socket end of each adjusting screw is stamped ``R''
or ``L'' to indicate use on right or left side of vehicle. Adjusting pivot nuts can be identified by
number of lines machined around body of nut. Two lines indicate righthand nut and one line
indicates lefthand nut.
7. Position cable in cable guide and install cable anchor fitting on the anchor pin.
8. Install parking brake assembly in anchor pin and secure with retaining nut behind backing plate.
9. On vehicles with full-floating axles, install brake drums as follows:
a. Place brake drum on hub and install attaching screws, bolts, or bolts and nuts. b. Place hub and
drum as an assembly on axle and start adjusting nut. c. Adjust wheel bearing nut and install wheel
bearing lock washer and lock nut. See REAR AXLE for procedure. d. Install new gasket and the
bolts and lock washers. e. Install wheel and tire assembly. f.
Adjust brakes. Refer to individual truck chapter for correct adjustment procedure.
10. On vehicles with semi-floating axles, install brake drums as follows:
a. Adjust brakes. Refer to individual truck chapter for correct adjustment procedure. b. Install drum.
c. Install brake drum retaining nuts and tighten securely. d. Install wheel on axle shaft flange studs
against drum, and tighten retaining nuts.
11. If any hydraulic connections have been opened, perform system brake bleeding procedures.
12. Check master cylinder fluid level, filling as necessary.
13. Check brake pedal for proper feel and return.
14. Lower vehicle and road test.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Installation > Page 2615
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Technical Service Bulletins > Customer Interest: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear
Wheel Cylinder: Customer Interest Brakes (Rear) - Accelerated Wear
Articles No. 84-16-28
BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES
LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO
This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E &
F-100/150 & Bronco vehicles that have 11" diameter rear brakes.
Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban
delivery/service operations may experience accelerated rear brake wear. A service
kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the
vehicle exhibits any of the following conditions:
^ Side to side imbalance in rear braking effectiveness.
^ Side to side imbalance in rear brake lining wear.
^ Excessive heat ("blued" shoes and/or drums).
The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a
proportioning valve. These parts must be installed per the appropriate shop manual installation
procedure.
NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake
backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before
installing the service kit (E0UZ-2C178-A).
PART NUMBER PART NAME CLASS
E0UZ-2C178-A Brake Service Kit C
Front/Rear Services
OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION:
SP2178A83 TIME:
2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear
Wheel Cylinder: All Technical Service Bulletins Brakes (Rear) - Accelerated Wear
Articles No. 84-16-28
BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES
LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO
This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E &
F-100/150 & Bronco vehicles that have 11" diameter rear brakes.
Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban
delivery/service operations may experience accelerated rear brake wear. A service
kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the
vehicle exhibits any of the following conditions:
^ Side to side imbalance in rear braking effectiveness.
^ Side to side imbalance in rear brake lining wear.
^ Excessive heat ("blued" shoes and/or drums).
The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a
proportioning valve. These parts must be installed per the appropriate shop manual installation
procedure.
NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake
backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before
installing the service kit (E0UZ-2C178-A).
PART NUMBER PART NAME CLASS
E0UZ-2C178-A Brake Service Kit C
Front/Rear Services
OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION:
SP2178A83 TIME:
2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Wheel Cylinder: > NHTSA82V104000 > Oct > 82 > recall
82V104000: Rear Axle Nut Inspection
Axle Nut: All Technical Service Bulletins recall 82V104000: Rear Axle Nut Inspection
ON CERTAIN VEHICLES, THE LOCK WEDGES USED TO SECURE THE AXLE BEARING NUTS
TO THE AXLE HOUSING MAY FALL OUT OF POSITION, ALLOWING THE NUT TO LOOSEN.
THE NUT ON THE LEFT SIDE MAY FALL OFF, ALLOWING MOVEMENT OF THE AXLE SHAFT.
THE DEALER WILL REPLACE DEFECTIVE LOCK WEDGES WITH AN IMPROVED VERSION.
WHEEL BEARINGS WILL BE INSPECTED AND ADJUSTED OR REPLACED, IF NECESSARY.
VEHICLE DESCRIPTION: LIGHT TRUCKS WITH DANA FULL-FLOATING REAR AXLES.
SYSTEM: POWER TRAIN; REAR AXLE ASSEMBLY. CONSEQUENCES OF DEFECT: THIS
COULD RESULT IN PARTIAL LOSS OF BRAKING ACTION OR PARTIAL OR TOTAL
SEPARATION OF THE LEFT REAR WHEEL AND BRAKE ASSEMBLY.IN EITHER CASE, LOSS
OF VEHICLE CONTROL AND AN ACCIDENT COULD FOLLOW.
1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK F250 1982 FORD
TRUCK F350 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK F250
1983 FORD TRUCK F350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair
Brake Bleeding: Service and Repair
Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on
each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has
been drained from hydraulic system.
1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to
absorb escaping brake fluid.
2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at
fitting.
3. Hold pedal down and tighten fittings, then release brake pedal. Releasing brake pedal before
fittings are tightened will allow air to enter the master cylinder.
4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm.
5. Bleed rear brakes as follows:
a. Pump pedal several times, then hold pedal down firmly. b. With pedal firmly depressed, open
bleeder screw on one rear brake until pedal fades to floor, then close bleeder valve. c. Repeat
procedure until a continuous flow of brake fluid is released from bleeder valve. d. Repeat steps 5a
through 5c on other rear brake.
6. Bleed front brakes using same procedure as for rear brakes.
7. Fill master cylinder reservoirs to {1/4} inch from top of reservoirs.
8. Centralize the pressure differential control valve, if applicable, as follows:
a. Turn ignition switch to ``ACC'' or ``On'' position. b. Push brake pedal down, allowing piston to
center itself, turning off warning light. c. Turn ignition switch to ``OFF'' position.
9. Check brake operation and ensure pedal is firm, then road test vehicle.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear
Brake Caliper: Customer Interest Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 2651
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 2652
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 2653
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 2654
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 2655
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 2656
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 2657
OASIS CODES: 301000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 86621 > Mar > 86 > Front Disc Brakes Clunk During Braking
Brake Caliper: Customer Interest Front Disc Brakes - Clunk During Braking
Article No. 86-6-21
BRAKES - FRONT DISC - CLUNK
LIGHT TRUCK 1980-85 E250/350, F250/350
Some 1980-85 250/350 Econoline and F Series vehicles over 6900 GVW are experiencing front
disc brake clunk during braking. This concern can be corrected by using new caliper support keys
and springs as outlined in the following procedure.
1. Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coat of
ESAM1C172-A (D7AZ-19590-A) lubricant to both surfaces, being careful not to get lubricant on
rotors or linings.
2. Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the
Light Truck Shop Manual procedures, Section 11- 10 and 11-12.
3. Discard the old caliper support key and spring and reinstall the caliper using a new service key
(D7TZ- 2B487-B) and spring (D7TZ-2B486-B).
PART NUMBER PART NAME CLASS
D7TZ-2B487-B Support Key A
D7TZ-2B486-B Spring A
D7AZ-19590-A Lubricant A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP2487A86 TIME:
0.6 Hr. DLR. CODING: Basic Part No. 2B487 - Code: 33
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear
Brake Caliper: All Technical Service Bulletins Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 2667
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 2668
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 2669
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 2670
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 2671
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 2672
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 2673
OASIS CODES: 301000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 86621 > Mar > 86 > Front
Disc Brakes - Clunk During Braking
Brake Caliper: All Technical Service Bulletins Front Disc Brakes - Clunk During Braking
Article No. 86-6-21
BRAKES - FRONT DISC - CLUNK
LIGHT TRUCK 1980-85 E250/350, F250/350
Some 1980-85 250/350 Econoline and F Series vehicles over 6900 GVW are experiencing front
disc brake clunk during braking. This concern can be corrected by using new caliper support keys
and springs as outlined in the following procedure.
1. Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coat of
ESAM1C172-A (D7AZ-19590-A) lubricant to both surfaces, being careful not to get lubricant on
rotors or linings.
2. Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the
Light Truck Shop Manual procedures, Section 11- 10 and 11-12.
3. Discard the old caliper support key and spring and reinstall the caliper using a new service key
(D7TZ- 2B487-B) and spring (D7TZ-2B486-B).
PART NUMBER PART NAME CLASS
D7TZ-2B487-B Support Key A
D7TZ-2B486-B Spring A
D7AZ-19590-A Lubricant A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP2487A86 TIME:
0.6 Hr. DLR. CODING: Basic Part No. 2B487 - Code: 33
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper Removal
Brake Caliper: Service and Repair Caliper Removal
Fig. 1 Bottoming caliper piston in cylinder bore
1. Remove a portion of brake fluid from master cylinder disc brake reservoir.
2. Raise and support vehicle and remove wheel and tire assembly.
3. Install eight inch C-clamp on caliper, Fig. 1, and tighten clamp to bottom piston in cylinder bore,
then remove clamp. Do not use screwdriver or other edged tool to pry piston from rotor.
4. Remove key retaining screw, then using hammer and drift, drive out caliper support key and
spring.
5. Remove caliper by pushing it downward against spindle assembly and rotating upper end
upward and out of spindle assembly.
6. Disconnect hydraulic line from caliper.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper Removal > Page 2680
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper Removal > Page 2681
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Caliper Removal > Page 2682
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch
> Component Information > Locations
Brake Fluid Pressure Sensor/Switch: Locations
Frame Wiring.
On LH Frame At No. 2 Crossmember
Applicable to: 138 Standard Van
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake
Proportioning/Combination Valve: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear
Brake Proportioning/Combination Valve: All Technical Service Bulletins Brakes (Rear) Accelerated Wear
Articles No. 84-16-28
BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES
LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO
This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E &
F-100/150 & Bronco vehicles that have 11" diameter rear brakes.
Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban
delivery/service operations may experience accelerated rear brake wear. A service
kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the
vehicle exhibits any of the following conditions:
^ Side to side imbalance in rear braking effectiveness.
^ Side to side imbalance in rear brake lining wear.
^ Excessive heat ("blued" shoes and/or drums).
The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a
proportioning valve. These parts must be installed per the appropriate shop manual installation
procedure.
NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake
backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before
installing the service kit (E0UZ-2C178-A).
PART NUMBER PART NAME CLASS
E0UZ-2C178-A Brake Service Kit C
Front/Rear Services
OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION:
SP2178A83 TIME:
2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination
Valve: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear
Brake Proportioning/Combination Valve: Customer Interest Brakes (Rear) - Accelerated Wear
Articles No. 84-16-28
BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES
LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO
This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E &
F-100/150 & Bronco vehicles that have 11" diameter rear brakes.
Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban
delivery/service operations may experience accelerated rear brake wear. A service
kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the
vehicle exhibits any of the following conditions:
^ Side to side imbalance in rear braking effectiveness.
^ Side to side imbalance in rear brake lining wear.
^ Excessive heat ("blued" shoes and/or drums).
The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a
proportioning valve. These parts must be installed per the appropriate shop manual installation
procedure.
NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake
backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before
installing the service kit (E0UZ-2C178-A).
PART NUMBER PART NAME CLASS
E0UZ-2C178-A Brake Service Kit C
Front/Rear Services
OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION:
SP2178A83 TIME:
2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > Page 2699
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Technical Service Bulletins > Brake Master Cylinder - Rebuilding Procedure
Brake Master Cylinder: Technical Service Bulletins Brake Master Cylinder - Rebuilding Procedure
Article No. 83-19-14
BRAKE MASTER CYLINDERS - REBUILDING PROCEDURE
LIGHT TRUCKS 1981-84 ALL LIGHT TRUCKS
Rebuilding of brake master cylinders during the vehicle warranty period for the subject vehicles has
been authorized. Service kits (Base Part Number 2004) are now available for all light truck series
vehicles. The following procedure is recommended for rebuilding:
DISASSEMBLY
1. Clean the outside of the master cylinder and remove the filler cover and diaphragm. Drain and
discard any brake fluid that remains in the cylinder.
2. Depress the primary piston and remove snap ring from retaining groove at the rear of the master
cylinder bore.
3. Remove primary piston assembly from the master cylinder bore and inspect for seal damage or
twisting. Record condition of piston assembly on service order and discard assembly.
4. Remove the secondary piston assembly by directing compressed air into the outlet port at the
blind end of the bore while plugging the other outlet port. Inspect for seal damage or twisting.
Record condition of piston assembly on service order and discard assembly.
5. Inspect the master cylinder bore for signs of etching, pitting, scoring or other damage.
a. If bore is damaged, discard and replace with new master cylinder assembly. Do not attempt to
hone bore.
b. If bore is not damaged, rebuild master cylinder assembly using the proper service kit and the
procedure outlined below.
ASSEMBLY
1. Clean the master cylinder body with clean isopropyl alcohol to remove any contamination.
2. Dip the service kit piston assemblies in clean brake fluid (ESA-M6C25-A) to lubricate seals.
3. Carefully insert the complete secondary piston assembly in the master cylinder bore.
4. Carefully insert the primary piston assembly in the master cylinder bore.
5. Depress the primary piston and install the snap ring in the cylinder bore groove.
6. On manual brake vehicles, install the push rod retainer onto the push rod and install into the
primary piston. Make sure the retainer is properly seated and holding the push rod securely.
7. Install the cover and gasket on the master cylinder assembly and secure into position with the
retainer.
OTHER APPLICABLE ARTICLES: 80-21-14 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time
Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 2004 Code: 53
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Technical Service Bulletins > Page 2704
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Technical Service Bulletins > Page 2705
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Technical Service Bulletins > Page 2706
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cylinder: > 841628 > Jul > 84 > Brakes
(Rear) - Accelerated Wear
Wheel Cylinder: All Technical Service Bulletins Brakes (Rear) - Accelerated Wear
Articles No. 84-16-28
BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES
LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO
This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E &
F-100/150 & Bronco vehicles that have 11" diameter rear brakes.
Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban
delivery/service operations may experience accelerated rear brake wear. A service
kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the
vehicle exhibits any of the following conditions:
^ Side to side imbalance in rear braking effectiveness.
^ Side to side imbalance in rear brake lining wear.
^ Excessive heat ("blued" shoes and/or drums).
The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a
proportioning valve. These parts must be installed per the appropriate shop manual installation
procedure.
NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake
backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before
installing the service kit (E0UZ-2C178-A).
PART NUMBER PART NAME CLASS
E0UZ-2C178-A Brake Service Kit C
Front/Rear Services
OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION:
SP2178A83 TIME:
2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Technical Service Bulletins > Customer Interest for Wheel Cylinder: > 841628 > Jul > 84 > Brakes (Rear) Accelerated Wear
Wheel Cylinder: Customer Interest Brakes (Rear) - Accelerated Wear
Articles No. 84-16-28
BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES
LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO
This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E &
F-100/150 & Bronco vehicles that have 11" diameter rear brakes.
Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban
delivery/service operations may experience accelerated rear brake wear. A service
kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the
vehicle exhibits any of the following conditions:
^ Side to side imbalance in rear braking effectiveness.
^ Side to side imbalance in rear brake lining wear.
^ Excessive heat ("blued" shoes and/or drums).
The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a
proportioning valve. These parts must be installed per the appropriate shop manual installation
procedure.
NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake
backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before
installing the service kit (E0UZ-2C178-A).
PART NUMBER PART NAME CLASS
E0UZ-2C178-A Brake Service Kit C
Front/Rear Services
OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION:
SP2178A83 TIME:
2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Technical Service Bulletins > Parking Brake Cables - New Plastic Coated Design
Parking Brake Cable: Technical Service Bulletins Parking Brake Cables - New Plastic Coated
Design
Article No. 83-14-19
PARKING BRAKE CABLE - PLASTIC COATED - SERVICE RELEASE
LIGHT TRUCKS 1980-82 E, F & BRONCO
New plastic coated parking brake cables have been released to service 1980-82 E, F and Bronco
vehicles. These new cables will result in improved resistance to corrosion and contamination and
should be considered for vehicles. The rear cables are packaged in kit form and require both
cables to be installed when replacing the prior level cables. The kit also contains other rear brake
components that should be installed at that time.
New plastic coated front parking brake cables are also released for all 1980-82 F Series, Bronco,
and Econoline vehicles. It is not always necessary to replace the front cables along with the rear
cables; the vehicle must be inspected first to determine which cables require replacement.
REAR PARKING BRAKE KITS Model
Kit Number
F-100/150/Bronco 11" Rear Brake E0TZ-2A753-A
F-100 10" Rear Brake E0TZ-2A753-B
F-250/350 12" Rear Brake E0TZ-2A753-C
E-100/150 11" Rear Brake E0UZ-2A753-A
E-250/350 12" Rear Brake E0UZ-2A753-B
FRONT PARKING BRAKE CABLE
Model Wheel Base Part Number
F Series 117" E0TZ-2853-K
133" E0TZ-2853-L
138" E0TZ-2853-M
155" E0TZ-2853-N
161" E0TZ-2853-R
Bronco E0TZ-2853-S
Econoline 124" E0UZ-2853-A
138" E0UZ-2853-B
158" E0UZ-2853-C
176" E0UZ-2853-D
PART NUMBER PART NAME CLASS
E0TZ-2A753-A 11" Rear Parking Brake Kit C
F100/150/Bronco
E0TZ-2A753-B 10" Rear Parking Brake Kit C
F100
E0TZ-2A753-C 12" Rear Parking Brake Kit C
F250/350
E0UZ-2A753-A 11" Rear Parking Brake Kit C
E100/150
E0UZ-2A753-B 12" Rear Parking Brake Kit C
E250/350
E0TZ-2853-K Front Parking Brake Cable C
F Series 117"
E0TZ-2853-L Front Parking Brake Cable C
F Series 133"
E0TZ-2853-M Front Parking Brake Cable C
F Series 138"
E0TZ-2853-N Front Parking Brake Cable C
F Series 155"
E0TZ-2853-R Front Parking Brake Cable C
F Series 161"
E0TZ-2853-S Front Parking Brake Cable C
Bronco
E0UZ-2853-A Front Parking Brake Cable C
Econoline 124"
E0UZ-2853-B Front Parking Brake Cable C
Econoline 138"
E0UZ-2853-C Front Parking Brake Cable C
Econoline 158"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Technical Service Bulletins > Parking Brake Cables - New Plastic Coated Design > Page 2725
E0UZ-2853-D Front Parking Brake Cable C
Econoline 176"
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Adjustments
Parking Brake Control: Adjustments
EXC. 1985-87 E-350 W/ORSCHEIN PARKING BRAKE LEVER
1. Position parking brake pedal to fully released position, then tighten equalizer nut 6 full turns
while preventing automatic adjuster from turning.
2. Depress parking brake pedal fully and measure cable tension. Cable tension should meet the
following specifications: 1980 front cable with parking brake set in second notch, 120-160 lbs., and
1981-87 rear cable with parking brake fully applied, 350 lbs.
3. If cable tension is not within specifications, repeat step 3 and recheck.
4. Release parking brake and check for rear wheel drag. If brake drag is noted on 1983---87
E-250---350 & F-250---350 models and 1980---82 E-250---350 models after brake adjustment,
remove rear drums and measure clearance between parking brake lever and cam plate. This
clearance should be .015 inch with brakes fully released. If clearance is not .015 inch, repeat cable
adjustment procedure.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Description and Operation
Vacuum Brake Booster: Description and Operation
The single and tandem vacuum boosters are self contained vacuum hydraulic power braking units.
These are vacuum suspended units that use vacuum and atmospheric pressure for their power. On
gasoline engine vehicles, vacuum is supplied through a fitting in the intake manifold. On diesel
engine vehicles, vacuum is supplied through a vacuum pump. The three basic elements of the
booster are the vacuum power chamber, mechanically actuated booster check valve and a
hydraulic dual master cylinder which supplies hydraulic pressure to the brake system. The vacuum
power chamber consists of a front and rear shell, diaphragm, diaphragm plate, hydraulic pushrod
and vacuum diaphragm return spring. The mechanically actuated booster check valve controls the
degree of power brake application in accordance with foot pressure applied to the valve operating
rod through the brake pedal linkage. This valve is integral with the vacuum power diaphragm.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Description and Operation > Page 2736
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Locations
Brake Fluid Pressure Sensor/Switch: Locations
Frame Wiring.
On LH Frame At No. 2 Crossmember
Applicable to: 138 Standard Van
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Pedal Position
Switch <--> [Clutch Switch] > Component Information > Testing and Inspection
Clutch Pedal Position Switch: Testing and Inspection
Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized
tools near this switch.
1. If the switch is open when the clutch pedal is released, speed control will not operate. This must
be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher
when performing the clutch switch test.
2. Disconnect switch pigtail connector from speed control harness connector and connect an
ohmmeter to the two switch connector terminals.
3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With
clutch pedal fully depressed, the circuit should be open.
4. If switch does not function as described, remove and replace switch.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Component Information > Service and Repair
Ignition Switch: Service and Repair
Fig. 3 Ignition switch replacement
1. Disconnect battery ground cable.
2. Remove steering column shroud and lower the steering column.
3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts.
4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Location For C6 Transmission
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 2755
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
RH Fender Apron w/EEC
On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins >
Auxiliary Battery Relay - Improved Design
Battery: Technical Service Bulletins Auxiliary Battery Relay - Improved Design
Article No. 85-21-12
WIRING - AUXILIARY BATTERY RELAY-IMPROVED WEATHER RESISTANT DESIGN
LIGHT TRUCK 1973-86 E, F SERIES, BRONCO
Figure 14 - ECONOLINE LOCATION
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins >
Auxiliary Battery Relay - Improved Design > Page 2764
Figure 15 - F-150/350 TRUCK AND BRONCO LOCATION
An improved weather resistant auxiliary battery relay has been released for the subject vehicles
equipped with an auxiliary battery. (See Figures 14 and 15)
The new relay (E5TZ-14677-A) is a direct replacement for the old relay, D3TZ-14377-B, which has
been discontinued.
PART NUMBER PART NAME CLASS
E5TZ-14677-A Auxiliary Battery Relay A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Diode Trio, Alternator > Component
Information > Testing and Inspection
Diode Trio: Testing and Inspection
Fig. 9 Regulator plug. Jumper wire connection
Test Procedure
1. Disconnect electric choke, if equipped.
2. Disconnect voltage regulator wiring connector.
3. Connect a jumper wire between the ``A'' and ``F'' terminals of the voltage regulator wiring
connector, Fig. 9.
4. Connect voltmeter to battery clamps. Then, start and idle engine.
5. Observe and note voltmeter reading.
6. Move the voltmeter positive lead to the alternator ``S'' terminal and note voltage reading.
Test Results
1. If voltmeter reading is within {1/2} of battery voltage, the diodes are satisfactory.
2. If voltmeter reading is approximately 1.5 volts, the alternator has a shorted negative diode or a
grounded stator winding.
3. If voltmeter reading is approximately 1.5 volts less than battery voltage, the alternator has a
shorted positive diode.
4. If voltage reading is approximately 1 to 1.5 volts less than {1/2} battery voltage, the alternator
has an open positive diode.
5. If voltage reading is 1 to 1.5 volts above {1/2} battery voltage, the alternator has an open
negative diode.
6. Reconnect electric choke into circuit after tests are completed, if equipped.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator >
Component Information > Technical Service Bulletins > Alternator - Rectifier Bench Test Procedure
Rectifier Diode / Bridge: Technical Service Bulletins Alternator - Rectifier Bench Test Procedure
Article No. 84-3-5
ALTERNATOR - RECTIFIER BENCH TEST PROCEDURE
FORD ALL
LINCOLN-MERCURY ALL
LIGHT TRUCKS ALL
MEDIUM/HEAVY TRUCKS ALL
During a recent dealer survey, it was discovered that some technicians are using digital meters for
alternator testing, despite specific instructions in the Shop Manual to the contrary. The digital
meters cannot be used for checking rectifier assemblies or diodes in the alternator. This may
explain a portion of non-defective rectifiers returned under warranty.
Alternator Rectifier Testing Information
The use of digital meters when bench testing an alternator rectifier assembly can cause
misdiagnosis. It is recommended in the Shop Manual (Section 31) that a Rotunda Meter Model
#059-00003, or equivalent, be used. Equivalent test meters must be of the "analog" type, not
digital. A digital meter could only be used if it has a diode checking function. However, the readings
should be compared with those of a new part to confirm the results.
If the rectifier is found to be okay, check for possible pinched or grounded wires to the inside of the
housing. Then reassemble the alternator with the tested rectifier. The Shop Manual Charging
System Diagnostic Procedure should be reviewed to confirm proper procedures were used.
Remember to first check for proper drive belt tension and proper wire connections at the alternator
and voltage regulator.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator >
Component Information > Technical Service Bulletins > Page 2774
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator >
Component Information > Technical Service Bulletins > Page 2775
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator >
Component Information > Technical Service Bulletins > Page 2776
7. If ohmmeter reads less than infinite at either point, a grounded brush lead, grounded rotor or
defective regulator is indicated.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component
Information > Testing and Inspection
Stator: Testing and Inspection
Fig. 13 Testing diode trio
Fig. 14 Alternator w/integral regulator rectifier short or grounded & stator grounded test
RECTIFIER SHORT OR GROUNDED & STATOR GROUNDED TEST Using a suitable ohmmeter,
connect one probe to the alternator BAT terminal, Figs. 13 and 14, and the other probe to the STA
terminal (rear blade terminal). Then, reverse the ohmmeter probes and repeat the test. A reading of
about 6.5 ohms should be obtained in one direction and no needle movement with the probes
reversed. A reading in both directions indicates a bad positive diode, a grounded positive diode
plate or a grounded BAT terminal. Perform the same test using the STA and GND (ground)
terminals of the alternator. A reading in both directions indicates either a bad negative diode, a
grounded stator winding, a grounded stator terminal, a grounded positive diode plate, or a
grounded BAT terminal. Infinite readings (no needle movement) in all four probe positions in the
preceding tests indicates an open STA terminal lead connection inside the alternator.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component
Information > Testing and Inspection > Page 2780
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component
Information > Testing and Inspection > Page 2781
7. If ohmmeter reads less than infinite at either point, a grounded brush lead, grounded rotor or
defective regulator is indicated.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Specifications
Voltage Regulator: Specifications
Measure battery voltage and record figure. With engine operating off idle and all secondary
electrical systems turned off, regulated voltage should be no greater than 2 volts above recorded
figure. Turn on headlights and set heater blower to high. Regulated voltage off idle should be no
less than 0.5 volts above recorded figure.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Pedal Position Switch <--> [Clutch Switch] >
Component Information > Testing and Inspection
Clutch Pedal Position Switch: Testing and Inspection
Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized
tools near this switch.
1. If the switch is open when the clutch pedal is released, speed control will not operate. This must
be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher
when performing the clutch switch test.
2. Disconnect switch pigtail connector from speed control harness connector and connect an
ohmmeter to the two switch connector terminals.
3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With
clutch pedal fully depressed, the circuit should be open.
4. If switch does not function as described, remove and replace switch.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] >
Component Information > Description and Operation
Ignition Resistor: Description and Operation
The ballast resistor, (wire type), maintains a specific resistance between the positive (Batt.)
terminal of the ignition coil connector and the wiring harness connector. It is not in operation during
engine cranking enabling the coil to receive a hotter signal for starting. Once the engine is running,
the resistor is used to protect the coil from voltage overload.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] >
Component Information > Description and Operation > Page 2792
Ignition Resistor: Testing and Inspection
1. Disconnect module connector with red and white wires then, ignition coil connector.
2. Using a suitable ohmmeter, measure resistance between Batt. terminal of ignition coil connector
and wiring harness connector wire that joins red wire in module connector.
3. If resistance is 0.8---1.6 ohms, ballast resistor is satisfactory. If resistance is less than 0.8 ohms
or greater than 1.6 ohms, replace ballast resistor.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams >
Connector Views
Ignition Lock: Connector Views
For Connector Views, please refer to: Ignition Switch/Diagrams,
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams >
Connector Views > Page 2797
Ignition Lock: Electrical Diagrams
For Wiring Diagrams, please refer to: Starting System/Diagrams,
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams >
Page 2798
Ignition Lock: Service and Repair
Fig. 1 Ignition lock replacement. Fixed steering column
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams >
Page 2799
Fig. 2 Ignition lock replacement. Tilt steering column
1. Disconnect battery ground cable.
2. Remove steering wheel trim pad and steering wheel.
3. Shift transmission into Park on vehicles with automatic transmission, or into any gear on vehicles
with manual transmission.
4. Insert a {1/8} inch diameter wire or small drift punch into retaining pin access slot and remove
lock cylinder, Figs. 1 and 2, while depressing pin. The lock cylinder retaining pin is located adjacent
to the hazard warning button on models with tilt steering column and inside the column near base
of cylinder on models with fixed steering column.
5. To install, turn lock cylinder to On position and depress pin.
6. Install lock cylinder into housing. Turn ignition key to Off position after ensuring cylinder is fully
seated and aligned into interlocking washer.
7. Turn the key to check for proper operation in all positions.
8. Install steering wheel and trim pad and reconnect battery ground cable.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Service
and Repair
Ignition Switch: Service and Repair
Fig. 3 Ignition switch replacement
1. Disconnect battery ground cable.
2. Remove steering column shroud and lower the steering column.
3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts.
4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
Location For C6 Transmission
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 2806
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component
Information > Testing and Inspection > Armature & Field Grounded Circuit Test
Starter Armature: Testing and Inspection Armature & Field Grounded Circuit Test
Fig. 4 Field grounded circuit test connections
1. Connect jumper lead to positive battery terminal.
2. Connect negative voltmeter lead to negative battery terminal.
3. Touch positive voltmeter lead to commutator and jumper wire to armature.
4. If voltmeter indicates voltage, armature windings are grounded.
5. Make connections as shown, Fig. 4. If voltmeter indicates voltage, field windings are grounded.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component
Information > Testing and Inspection > Armature & Field Grounded Circuit Test > Page 2812
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision
Technical Service Bulletin # 9211B1 Date: 920605
Starter Motor Brushes - Replacement Revision
Article No. 92-11B-1
06/05/92
^ SHOP MANUAL - 1982 THROUGH 1991 AS APPLICABLE - STARTER - POSITIVE
ENGAGEMENT - STARTER MOTOR BRUSHES REPLACEMENT PROCEDURE FOR 4-INCH
STARTERS REVISED/ADDED
^ SHOP MANUAL - 1990 AND 1991 AS APPLICABLE - STARTER - POSITIVE ENGAGEMENT STARTER SIZE SPECFICATION REVISED
FORD: 1989 CROWN VICTORIA, ESCORT, TEMPO 1989-90 THUNDERBIRD 1989-91
MUSTANG, TAURUS
LINCOLN-MERCURY: 1989 CONTINENTAL, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR
1989-90 COUGAR 1989-91 SABLE
LIGHT TRUCK: 1982-91 BRONCO, ECONOLINE, F-150-350 SERIES 1983-91 RANGER 1984-90
BRONCO II 1986-91 AEROSTAR 1988-91 F SUPER DUTY
ISSUE: The procedure for Starter Motor Brushes Replacement applicable to vehicles with 4-inch
starters only is missing or incorrect in the "Starter-Positive Engagement" section of certain Shop
Manuals. Additionally, the 1990 and 1991 Light Truck Shop Manuals incorrectly show a 3-inch
starter in the Specifications Chart; the correct size is 4-inch. The following Shop Manuals are
affected in the Sections indicated:
^ 1989 Domestic Car Lines: Section 28-02
^ 1990 Mustang, Taurus/Sable, Thunderbird/Cougar: Section 28-02
^ 1991 Mustang, Taurus/Sable: Section 28-02
^ 1986 through 1988 Aerostar: Section 11-02
^ 1989 Aerostar, Ranger, Bronco II: Section 03-06
^ 1990 and 1991 Aerostar, Ranger, Bronco II: Section 03-06A
^ 1983 Ranger/1984 Bronco II (Reprint), 1984 through 1988 Ranger/Bronco II, 1982 through 1990
Light Truck-Engine: Section 28-02
^ 1991 Light Truck-Engine: Section 03-06A
ACTION: Refer to Disassembly and Assembly in this TSB article for the additional information.
NOTE: THIS TSB ARTICLE INCLUDES REVISED PAGES FROM THE 1989, 1990 AND 1991
CAR SHOP MANUALS LISTED ABOVE, THE 1991 COMPACT TRUCK SHOP MANUAL AND
THE 1990 AND 1991 LIGHT TRUCK SHOP MANUALS. ALTHOUGH NOT SHOWN, THE
REVISIONS APPLY TO ALL LIGHT TRUCK AND COMPACT TRUCK MANUALS LISTED ABOVE.
NOTE: THE PROCEDURE IN THIS TSB ARTICLE APPLIES TO VEHICLES WITH 4-INCH
STARTERS ONLY.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2817
290000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2818
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2819
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2820
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2821
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2822
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2823
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2824
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2825
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2826
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2827
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2828
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2829
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2830
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2831
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2832
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2833
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2834
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2835
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2836
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2837
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Starter Relay: Locations
RH Fender Apron w/EEC
On RH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative
Fuse: Customer Interest A/C Blower Motor - Inoperative
Article No. 85-10-19
AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER
LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES
When operating the A/C system for long periods of time with the blower motor set on high, the
solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the
heat build-up. A revised fuse holder is released to resolve the subject concern.
The following procedure should be performed:
1. Check fuse for damage (solder melted at end of fuse).
2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat
build-up).
3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for
inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in
Steps 1 and 2 continue with Step 4.
4. Disconnect battery ground cable.
5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel.
6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close
to the fuse panel as possible and remove the fuse holders from the fuse panel.
7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page
2850
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor Inoperative
Fuse: All Technical Service Bulletins A/C Blower Motor - Inoperative
Article No. 85-10-19
AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER
LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES
When operating the A/C system for long periods of time with the blower motor set on high, the
solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the
heat build-up. A revised fuse holder is released to resolve the subject concern.
The following procedure should be performed:
1. Check fuse for damage (solder melted at end of fuse).
2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat
build-up).
3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for
inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in
Steps 1 and 2 continue with Step 4.
4. Disconnect battery ground cable.
5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel.
6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close
to the fuse panel as possible and remove the fuse holders from the fuse panel.
7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor Inoperative > Page 2856
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > Page 2857
Fuse: Locations
LH Shroud, Near Access Hole
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information
> Locations > Fuse Link B
Fusible Link: Locations Fuse Link B
Attached To Auxiliary Battery Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information
> Locations > Fuse Link B > Page 2862
Fusible Link: Locations Fuse Link C
Attached To Junction Block Or Auxiliary Battery Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information
> Locations > Fuse Link B > Page 2863
Fusible Link: Locations Fuse Link D
Attached To Junction Block Or Auxiliary Battery Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information
> Locations > Fuse Link B > Page 2864
Fusible Link: Locations Fuse Link E
At Starter Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information
> Locations > Fuse Link B > Page 2865
Fusible Link: Locations
Fuse Link B
Attached To Auxiliary Battery Relay
Fuse Link C
Attached To Junction Block Or Auxiliary Battery Relay
Fuse Link D
Attached To Junction Block Or Auxiliary Battery Relay
Fuse Link E
At Starter Relay
Fuse Link G
At Starter Relay
Fuse Link K
At Junction Block
Fuse Link L
Connected To Junction Block Or Auxiliary Battery Relay
Fuse Link M
At Starter Relay
Fuse Links A, G & H
Attached To Starter Motor Relay
Fuse Links G & H ( W/Ammeter)
In Harness, RH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Locations
Multiple Junction Connector: Locations
LH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Protection Relay > Component
Information > Locations
Power Protection Relay: Locations
In Engine Compartment On LH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Protection Relay > Component Information > Locations
Power Protection Relay: Locations
In Engine Compartment On LH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins >
Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative
Fuse: Customer Interest A/C Blower Motor - Inoperative
Article No. 85-10-19
AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER
LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES
When operating the A/C system for long periods of time with the blower motor set on high, the
solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the
heat build-up. A revised fuse holder is released to resolve the subject concern.
The following procedure should be performed:
1. Check fuse for damage (solder melted at end of fuse).
2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat
build-up).
3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for
inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in
Steps 1 and 2 continue with Step 4.
4. Disconnect battery ground cable.
5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel.
6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close
to the fuse panel as possible and remove the fuse holders from the fuse panel.
7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins >
Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 2885
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative
Fuse: All Technical Service Bulletins A/C Blower Motor - Inoperative
Article No. 85-10-19
AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER
LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES
When operating the A/C system for long periods of time with the blower motor set on high, the
solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the
heat build-up. A revised fuse holder is released to resolve the subject concern.
The following procedure should be performed:
1. Check fuse for damage (solder melted at end of fuse).
2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat
build-up).
3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for
inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in
Steps 1 and 2 continue with Step 4.
4. Disconnect battery ground cable.
5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel.
6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close
to the fuse panel as possible and remove the fuse holders from the fuse panel.
7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 2891
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins >
Page 2892
Fuse: Locations
LH Shroud, Near Access Hole
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link
B
Fusible Link: Locations Fuse Link B
Attached To Auxiliary Battery Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link
B > Page 2897
Fusible Link: Locations Fuse Link C
Attached To Junction Block Or Auxiliary Battery Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link
B > Page 2898
Fusible Link: Locations Fuse Link D
Attached To Junction Block Or Auxiliary Battery Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link
B > Page 2899
Fusible Link: Locations Fuse Link E
At Starter Relay
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link
B > Page 2900
Fusible Link: Locations
Fuse Link B
Attached To Auxiliary Battery Relay
Fuse Link C
Attached To Junction Block Or Auxiliary Battery Relay
Fuse Link D
Attached To Junction Block Or Auxiliary Battery Relay
Fuse Link E
At Starter Relay
Fuse Link G
At Starter Relay
Fuse Link K
At Junction Block
Fuse Link L
Connected To Junction Block Or Auxiliary Battery Relay
Fuse Link M
At Starter Relay
Fuse Links A, G & H
Attached To Starter Motor Relay
Fuse Links G & H ( W/Ammeter)
In Harness, RH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Locations
Multiple Junction Connector: Locations
LH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Power Protection Relay > Component Information > Locations
Power Protection Relay: Locations
In Engine Compartment On LH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Protection Relay > Component Information > Locations
Power Protection Relay: Locations
In Engine Compartment On LH Fender Apron
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull
Alignment: Customer Interest Steering - Drift/Pull
Article No. 85-19-15
STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT
LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350
A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift
or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to
increase the front wheel caster angle on either or both wheels to balance the caster split to correct
a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the
front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can
increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to
decrease caster.
To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the
following procedure is suggested:
1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop
Manual and choose the appropriate paper template applicable to the vehicle model.
Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM
2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a
typical arm modification for the right hand radius arm. One template per vehicle model is used to
modify both the right and left hand radius arms. When modifying the right hand arm, position the
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2920
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2921
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2922
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2923
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Customer Interest for Alignment: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear
Alignment: Customer Interest Tires - Front Outside Edge Wear
Article No. 85-19-16
TIRE WEAR - FRONT - OUTSIDE EDGE
LIGHT TRUCK 1976-86 E100-150
Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by
excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15
can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit
contains complete instructions for modifying the front radius arms and mounting a metal adjusting
cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch
along two sides of the cam to the lower flange of the radius arm.
Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5
degrees. Increasing caster more than 3 degrees is not recommended since this may cause
complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased
on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built
into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of
each axle.
Three other significant factors may also contribute to outboard shoulder wear. They are excessive
toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After
any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to
extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life.
PART NUMBER PART NAME CLASS
E5TZ-3K064-A Kit Caster Adjustment C
OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME:
4.6 Hrs.
OPERATION: 3001A TIME:
0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull
Alignment: All Technical Service Bulletins Steering - Drift/Pull
Article No. 85-19-15
STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT
LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350
A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift
or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to
increase the front wheel caster angle on either or both wheels to balance the caster split to correct
a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the
front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can
increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to
decrease caster.
To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the
following procedure is suggested:
1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop
Manual and choose the appropriate paper template applicable to the vehicle model.
Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM
2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a
typical arm modification for the right hand radius arm. One template per vehicle model is used to
modify both the right and left hand radius arms. When modifying the right hand arm, position the
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2933
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2934
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2935
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2936
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear
Alignment: All Technical Service Bulletins Tires - Front Outside Edge Wear
Article No. 85-19-16
TIRE WEAR - FRONT - OUTSIDE EDGE
LIGHT TRUCK 1976-86 E100-150
Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by
excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15
can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit
contains complete instructions for modifying the front radius arms and mounting a metal adjusting
cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch
along two sides of the cam to the lower flange of the radius arm.
Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5
degrees. Increasing caster more than 3 degrees is not recommended since this may cause
complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased
on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built
into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of
each axle.
Three other significant factors may also contribute to outboard shoulder wear. They are excessive
toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After
any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to
extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life.
PART NUMBER PART NAME CLASS
E5TZ-3K064-A Kit Caster Adjustment C
OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME:
4.6 Hrs.
OPERATION: 3001A TIME:
0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2941
Alignment: By Symptom
Technical Service Bulletin # 851916 Date: 850901
Tires - Front Outside Edge Wear
Article No. 85-19-16
TIRE WEAR - FRONT - OUTSIDE EDGE
LIGHT TRUCK 1976-86 E100-150
Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by
excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15
can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit
contains complete instructions for modifying the front radius arms and mounting a metal adjusting
cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch
along two sides of the cam to the lower flange of the radius arm.
Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5
degrees. Increasing caster more than 3 degrees is not recommended since this may cause
complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased
on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built
into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of
each axle.
Three other significant factors may also contribute to outboard shoulder wear. They are excessive
toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After
any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to
extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life.
PART NUMBER PART NAME CLASS
E5TZ-3K064-A Kit Caster Adjustment C
OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME:
4.6 Hrs.
OPERATION: 3001A TIME:
0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36
Technical Service Bulletin # 851915 Date: 850926
Steering - Drift/Pull
Article No. 85-19-15
STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT
LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350
A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift
or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to
increase the front wheel caster angle on either or both wheels to balance the caster split to correct
a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the
front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can
increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to
decrease caster.
To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the
following procedure is suggested:
1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop
Manual and choose the appropriate paper template applicable to the vehicle model.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2942
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2943
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2944
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2945
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2946
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2947
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2948
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2949
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2950
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All
Technical Service Bulletins for Alignment: > Page 2951
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 2952
Alignment: Specifications
Camber Caster Toe
Ride Height 3.25-3.50 in -1 3/4 to -1/4 deg +9 to +10 1/2 deg 1/32 in
3.50-3.75 in -1 1/2 to + 1/4 deg +8 1/2 to +9 3/4 deg 1/32 in
4.00-4.25 in -1/2 to + 1 1/4 deg +7 1/8 to +8 1/2 deg 1/32 in
4.25-4.50 in 0 to + 1 3/4 deg +6 1/2 to +7 3/4 deg 1/32 in
4.50-4.75 in + 1/2 to +2 1/4 deg +5 3/4 to +7 deg 1/32 in
5.00-5.25 in +1 1/2 to + 3 1/4 deg +4 5/8 to +6 deg 1/32 in
5.25-5.50 in +2 to +3 3/4 deg +4 to +5 1/2 deg 1/32 in
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 2953
Alignment: Service and Repair
Fig. 1 Measuring Ride Height
Fig. 7 Measuring riding height. 1980---85 F-100---350 & Bronco
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 2954
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 250 Van Workshop Manual (V8-460 7.5L (1982))
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 250 Van Workshop Manual (V8-460 7.5L (1982))
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 2964
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 881414 > Jul > 88 > Steering - Unequal Left and Right Turn Angles >
Page 2970
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Center Link: > 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Spindle
REMOVE
1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly.
3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the
dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the
spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7.
Disconnect the steering linkage from the spindle arm by removing the cotter pin and nut, and then
removing the tie rod end from the spindle arm
with tie Rod End Remover, TOOL-3290-D or equivalent.
8. Remove the nut and lockwasher from the lock pin, and remove the lock pin. 9. Remove the
upper and lower spindle pin plugs; then, drive the spindle pin out from the top of the axle and
remove the spindle and thrust bearing.
Remove the spindle pin seal and thrust bearing.
INSTALL
1. Make sure the spindle pin hole in the axle is free of nicks, burrs, corrosion or foreign material.
Clean up the bore as necessary and lightly coat the
surface with a lithium-base grease, Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or
equivalent.
2. Install a new spindle pin seal with the metal backing facing up towards the bushing into the
spindle. Gently press seal into position, being careful
not to distort the casing.
3. Install a new thrust bearing with the lip flange facing down towards the lower bushing. Press until
the bearing is firmly seated against the surface
of the spindle.
4. Lightly coat the bushing surfaces with grease and place the spindle in position on the axle. 5.
Hold the spindle with thrust bearing in place tight against the axle and measure the space between
the axle and the spindle at the top of the axle. If
the vehicle uses shims, select the proper shims and install.
6. Install the spindle pin with the "T" stamped on one end towards the top, and the notch in the pin
aligned with the lock pin hole in the axle. Insert
the spindle pin through the bushings and axle from the top until the spindle pin notch and axle lock
pin hole are in line.
7. Install the lock pin with the threads pointing forward and the wedge groove facing the spindle pin
notch. Firmly drive the lock pin into position
and mount the lockwasher and nut. Tighten the nut to 52-84 Nm (38-62 ft lb).
8. Install the spindle pin plugs into the threads at the top and bottom of the spindle. Tighten the
plugs to 48-67 Nm (35-50 ft lb). 9. Lubricate the spindle pin and bushings with Long-Life Lubricant
C1AZ-19590-BA (ESA-M1C75-B) or equivalent, through both fittings until
grease is visible seeping past the upper seal at the top and from the thrust bearing slip joint at the
bottom. If grease does not appear, recheck the installation procedure to correct the problem. Lack
of adequate lubrication will result in rapid failure of the spindle components.
10. Install the dust shield. 11. Pack the inner and outer bearing cone with bearing grease. Use a
bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand
working the grease through the cage behind the rollers.
12. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 13. Install the
outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin
and dust cap. 14. Install the caliper.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 2984
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
Four factors affect power operation of the steering system: fluid level and condition, drive belt
tension, pump pressure and steering gear adjustment. These should always be checked before
any major service operations are performed. Conditions such as, hard or loose steering, road
shock or vibrations are not always due to steering gear or pump, but are often related instead to
such factors as low tire pressure and front end alignment. These factors should be checked and
corrected before any adjustment of the steering gear is made.
CHECKING FLUID LEVEL
1. Run engine to normal operating temperature, then shut it off. Remove reservoir filler cap and
check oil level on dipstick. Level should be up to ``Full'' mark on dipstick.
2. If level is low, add power steering fluid to proper level on dipstick and replace filler cap. When
adding less than one pint of fluid, it is permissible to use automatic transmission fluid. When adding
larger quantities or when making a complete fluid change, it is recommended that special power
steering fluid be used.
3. When checking fluid level after system has been serviced, air must be bled from the system as
outlined under ``Bleeding System.''
BLEEDING SYSTEM
1. With wheels turned all the way to the left, add the recommended fluid to the ``Add'' mark on
dipstick.
2. Start engine. While running at fast idle, recheck fluid level and, if necessary, add fluid to the
``Add'' mark on dipstick.
3. Bleed system by turning wheels from side to side without hitting stops. Maintain fluid level just
above internal pump casting. Fluid with air in it will have a light tan appearance. This air must be
eliminated from fluid before normal steering action can be obtained.
4. Return wheels to center position and continue to run engine for two or three minutes, then shut it
off.
5. Road test vehicle to make sure steering functions normally and is free from noise.
6. Recheck fluid level, making sure level is at the ``Full'' mark.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Power Steering pump - Rotor and `C' Clip Changes
Power Steering Pump: Technical Service Bulletins Power Steering pump - Rotor and `C' Clip
Changes
Article No. 83-10-6
STEERING - POWER - PUMP - FORD ROTOR AND "C" CLIP CHANGES
FORD 1980 PINTO 1980-82 GRANADA, FORD 1980-83 MUSTANG, FAIRMONT, T-BIRD
1981-83 ESCORT 1982-83 EXP 1983 LTD, CROWN VICTORIA
LINCOLN-MERCURY 1980 BOBCAT, MONARCH, VERSAILLES 1980-82 MERCURY 1980-83
CAPRI, ZEPHYR, COUGAR, XR7, LINCOLN, MARK 1981-83 LYNX 1982-83 LN7,
CONTINENTAL 1983 MARQUIS, GRAND MARQUIS
LIGHT TRUCKS 1980-83 F100, 150, 250, 350 1980-83 BRONCO 1983 RANGER The rotor
identification mark for re-assembly and rotor retention "C" clip is changed.
Figure 8
CII pumps built since August 1982 no longer have rotors with the small triangular detent on the
counterbore to indicate that this is the up side when reassembling (Figure 8). When servicing a
pump built since that time it is necessary to determine which side has the larger counterbore and
face that side up. It is important that the larger counterbore be up or the "C" clip will not install
properly on the shaft. Then it would be necessary to remove the rotor from the cam, turn it over and
re-install the slippers and springs.
Also, pumps built since February of 1983 have different rotor retention "C" clip (Figure 8). Either
clip will fit on the shaft but the new clip is preferred. OTHER APPLICABLE ARTICLES: 83-6-7
WARRANTY STATUS: "INFORMATION ONLY"
SPECIAL INSTRUCTIONS: Face larger rotor counterbore up when re-assembling.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation
Power Steering Pump: Service and Repair Removal and Installation
E-100-350
1. Disconnect pressure and return lines from pump.
2. Loosen belt tension adjusting bolt fully.
3. On models equipped with A/C, remove pump mounting bracket to A/C compressor mounting
bracket attaching bolts.
4. On all models, remove pump and mounting brackets from vehicle.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 2995
Power Steering Pump: Service and Repair Disassembly
Fig. 1 Exploded view of Ford Model CII power steering pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 2996
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 2997
Power Steering Pump: Service and Repair Assembly
Fig. 1 Exploded view of Ford Model CII power steering pump
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 2998
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 2999
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3000
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3001
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3002
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3003
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3004
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3005
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3006
18. Install drive shaft key in slot in shaft. Support shaft on opposite side while installing key. Install
reservoir cap.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3007
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3008
Fig. 2 Removal & installation of return tube, control valve, driveshaft, ball bearing assembly &
driveshaft seal
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3009
Fig. 3 Removal & installation of rotating group
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 3010
Fig. 4 Removal & installation of sleeve assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service
Precautions
Steering Column: Service Precautions
When the steering column is installed in the vehicle it is not susceptible to damage through
ordinary use; however, when it is removed, care must be taken during handling. Such actions as a
sharp blow on the end of the steering shaft or shift levers, leaning on the column assembly or
dropping of the assembly could loosen or shear the plastic shear joints or rivets used to maintain
column rigidity. Hammering, jolting or bumping on the steering shaft and gearshift tube must be
avoided during all service operations. If the shear pins are broken, the controlled length of the
telescoping design will be altered making these components unfit for further service. When
removing the steering wheel, only a steering wheel puller designed for this purpose must be used.
It is important that only the specified screws, bolts and nuts be used during the assembly
procedure and torqued to specifications to insure proper breakaway action of the column under
impact. Avoid using excessively long bolts or fasteners as they may prevent a portion of the
steering column from collapsing. When replacing fasteners, replace with ones of the same part
number or equivalent. When removing or installing the steering wheel, ignition switch, lock cylinder,
turn signal switch, neutral start switch, back-up light switch or adjusting column shift manual
transmission linkage refer to the appropriate vehicle chapter.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service
Precautions > Page 3014
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation
Steering Column: Service and Repair Removal and Installation
1980-87 E100-350 SERIES Removal
1. Apply parking brake and disconnect battery ground cable.
2. Remove two flexible coupling to steering shaft flange attaching nuts.
3. Remove shift linkage rod(s) from steering column.
4. Set wheels in straight ahead position and mark relationship of steering wheel and steering
column for proper installation.
5. Remove screws from underneath steering wheel, then lift horn switch assembly from steering
wheel.
6. Disconnect horn switch wires by pulling spade terminal from blade connectors, then squeeze
J-clip ground wire terminal and pull it out of hole in steering wheel.
7. Remove horn switch assembly, then the steering wheel retaining nut.
8. Using suitable puller, remove steering wheel from shaft. When servicing a tilt steering column,
the steering wheel must be in the full ``UP'' position when removed.
9. Remove steering column floor opening cover plate screws.
10. On 1980-81 models, remove shroud by pulling shroud tabs out of clip at bottom of column.
11. On 1982-87 models, remove shroud by loosening screw at bottom, placing shift lever in ``1'' on
manual 3 speed and automatic transmission models, and spreading shroud and withdrawing it from
instrument panel opening while pulling up and away from column.
12. Remove instrument cluster column opening cover.
13. Remove two column bracket to pedal support bracket attaching screws.
14. Disconnect turn signal/hazard warning and ignition switch wiring harnesses.
15. Remove steering column from vehicle, then the support bracket from column.
Installation
1. Position steering column in vehicle.
2. Connect turn signal/hazard warning and ignition switch wiring harnesses.
3. Insert steering shaft flange through floor opening so that flange engages flexible coupling, then
raise steering column up to pedal support bracket and loosely install column support bolts. When
the column has been removed, the flange assembly will be fully telescoped into the column. Gently
tap flange down to engage flexible coupling.
4. Loosely install flexible coupling flange nuts and floor plate fasteners.
5. Position steering wheel into place with retaining nut, aligning marks made during removal, and
torque nut to 30-40 ft. lbs.
6. Connect spade terminal of horn switch wire to blade connector and press J-clip ground terminal
fully into threaded hole.
7. Center horn switch on steering wheel and install attaching screws.
8. On 1980-81 models, align steering column and flexible coupling as follows:
a. Pull steering column upward until flexible coupling is positioned between flat, and concaved
upward {1/10} inch. b. Torque steering column to support bracket and steering column opening
cover plate to dash panel bolts to 8-20 ft. lbs. c. Insert a .010 inch shim between flexible coupling
right safety pin and steering column lower flange cutout then turn steering wheel one
revolution clockwise.
d. If shim cannot be removed, loosen cover plate clamp and plate attaching bolts and realign
column until shim can be removed when rotating
steering wheel.
e. Insert .010 inch shim between flexible coupling left safety pin and lower flange cutout, then turn
steering wheel one revolution
counterclockwise and check as in step 8d.
f. Install trim cover.
9. On 1982-87 models, align steering column and flexible coupling as follows:
a. Check for coupling pin to flange cutout clearance of .160 inch, adjusting as necessary. b. Torque
flange coupling nuts to 14-21 ft. lbs., steering column to support bracket bolts to 19-27 ft. lbs.,
steering column floor opening cover
plate to dash panel bolts to 12-18 ft. lbs., and steering column opening cover clamp bolt to 12-18 ft.
lbs.
10. Attach shift linkage rod(s).
11. Connect battery ground cable.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 3017
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 3018
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 3019
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 3020
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 3021
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 3022
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 3023
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Sector Shaft > Component Information >
Adjustments
Sector Shaft: Adjustments
GEAR ADJUSTMENTS
There are two adjustments on the steering gear: worm bearing preload and pitman shaft overcenter
preload.
Prior to adjusting the steering gear, all
outside loads must be removed.
Fig. 3 Steering gear adjustments
Fig. 4 Checking adjustment with an inch pound torque wrench
WORM BEARING PRELOAD, ADJUST
1. Disconnect battery ground cable, then raise and support vehicle.
2. Remove pitman arm nut, then mark relationship of pitman arm to pitman shaft to aid during
reassembly.
3. Remove pitman arm using a suitable puller.
4. Loosen steering gear adjuster plug lock nut, then back off adjuster plug {1/4} turn, Fig. 3.
5. Remove horn pad or button to gain access to the steering wheel attaching nut.
6. Turn steering wheel gently in one direction to stop, then turn back {1/2} turn to position steering
gear away from ``high point'' load position. Do
not turn wheel hard against steering stops with pitman arm disconnected as damage to the gear
ball guides can result.
7. Position suitable inch pound torque wrench on steering wheel hub nut, Fig. 4, then while rotating
steering wheel with inch pound wrench through a
90 degree arc, record and measure ``bearing drag.'' Do not use an inch pound wrench of more
than 50 inch pound capacity.
8. Adjust worm bearing preload to specifications listed at end of section by turning adjuster plug
while measuring turning torque at steering wheel hub with inch pound wrench.
Worm bearing preload specification is in excess of ``bearing drag'' determined in previous step.
9. Torque adjuster plug lock nut to 25 ft. lbs., then recheck preload. Rotate steering wheel from
stop to stop. If steering gear feels ``lumpy'',
bearing damage is indicated. Gear should be disassembled and inspected as necessary.
PITMAN SHAFT OVERCENTER PRELOAD, ADJUST
1. Perform steps 1 through 9 of ``Worm Bearing Preload, Adjust'' procedure.
2. Turn steering wheel from one stop to the other while carefully counting the total turns required,
then turn wheel back exactly halfway to position steering gear at ``high point.''
3. Loosen lash adjuster screw lock nut, Fig. 3, then turn adjuster screw clockwise to remove gear
lash between ball nut and pinion shaft. Tighten lock
nut.
4. Check steering wheel turning torque with suitable inch pound wrench at steering wheel hub, Fig.
4, and compare to specifications listed at end of
section.
5. If measurement is not within specifications, loosen lock nut and readjust adjuster screw to obtain
proper turning torque. Tighten lock nut and check turning torque through center of steering wheel
travel.
If maximum turning torque exceeds specifications, turn adjuster screw
counterclockwise, then come up on adjustment by turning in a clockwise direction.
6. Assemble pitman arm to pitman shaft.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Description
and Operation
Axle Beam: Description and Operation
Fig. 1 Twin I-Beam front axle
Fig. 2 Spindle used with twin I Beam front axle. Typical
EXC. 4 WHEEL DRIVE MODELS
Twin I-Beam Axle As illustrated in Fig. 1 there are two I-beam axles, one for each front wheel. One
end of each axle is attached to the spindle and a radius arm and the other end is attached to a
frame bracket on the opposite side of the vehicle. Each spindle is held in place on the axle by ball
joints or a spindle bolt which pivots in bushings pressed in the upper and lower ends of the spindle,
Fig. 2. On models equipped with spindle bolts, a thrust bearing is installed between the lower end
of the axle and the spindle to support the load on the axle. On all models, a spindle arm is installed
on each spindle for attachment to the steering linkage.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Spindle
REMOVE
1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly.
3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the
dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the
spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7.
Disconnect the steering linkage from the spindle arm by removing the cotter pin and nut, and then
removing the tie rod end from the spindle arm
with tie Rod End Remover, TOOL-3290-D or equivalent.
8. Remove the nut and lockwasher from the lock pin, and remove the lock pin. 9. Remove the
upper and lower spindle pin plugs; then, drive the spindle pin out from the top of the axle and
remove the spindle and thrust bearing.
Remove the spindle pin seal and thrust bearing.
INSTALL
1. Make sure the spindle pin hole in the axle is free of nicks, burrs, corrosion or foreign material.
Clean up the bore as necessary and lightly coat the
surface with a lithium-base grease, Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or
equivalent.
2. Install a new spindle pin seal with the metal backing facing up towards the bushing into the
spindle. Gently press seal into position, being careful
not to distort the casing.
3. Install a new thrust bearing with the lip flange facing down towards the lower bushing. Press until
the bearing is firmly seated against the surface
of the spindle.
4. Lightly coat the bushing surfaces with grease and place the spindle in position on the axle. 5.
Hold the spindle with thrust bearing in place tight against the axle and measure the space between
the axle and the spindle at the top of the axle. If
the vehicle uses shims, select the proper shims and install.
6. Install the spindle pin with the "T" stamped on one end towards the top, and the notch in the pin
aligned with the lock pin hole in the axle. Insert
the spindle pin through the bushings and axle from the top until the spindle pin notch and axle lock
pin hole are in line.
7. Install the lock pin with the threads pointing forward and the wedge groove facing the spindle pin
notch. Firmly drive the lock pin into position
and mount the lockwasher and nut. Tighten the nut to 52-84 Nm (38-62 ft lb).
8. Install the spindle pin plugs into the threads at the top and bottom of the spindle. Tighten the
plugs to 48-67 Nm (35-50 ft lb). 9. Lubricate the spindle pin and bushings with Long-Life Lubricant
C1AZ-19590-BA (ESA-M1C75-B) or equivalent, through both fittings until
grease is visible seeping past the upper seal at the top and from the thrust bearing slip joint at the
bottom. If grease does not appear, recheck the installation procedure to correct the problem. Lack
of adequate lubrication will result in rapid failure of the spindle components.
10. Install the dust shield. 11. Pack the inner and outer bearing cone with bearing grease. Use a
bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand
working the grease through the cage behind the rollers.
12. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 13. Install the
outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin
and dust cap. 14. Install the caliper.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 3035
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information >
Technical Service Bulletins > King Pin - Service Procedure
Spindle Pin: Technical Service Bulletins King Pin - Service Procedure
Article No. 83-4-13
KING PIN SERVICE SPINDLE THREAD PROTECTION - VEHICLES WITH FORGED AXLES
LIGHT TRUCKS 1975-83 ECONOLINE & F100-350
TSB 82-11-8 dated June 4, 1982 described the recommended king pin service procedure and
referenced the use of a hydraulic press to remove the spindle pin. For dealerships that do not have
such a press and normally remove the spindle pin by using a drift pin, the following procedure is
suggested to prevent spindle damage.
1. Remove upper/lower grease plug from the spindle being serviced (both spindles if required).
2. Remove the zerk fitting from one of the grease plugs. Clean grease plug.
3. Using the zerk fitting hole as a piloting hole, drill out the grease plug to any desired diameter up
to a maximum of 3/4".
4. After drilling is complete, re-install the modified grease plug in upper spindle.
5. Remove spindle pin by inserting a drift pin through the hole in the grease plug and striking with a
mallet. The grease plug will provide protection for the threads in the spindle.
6. After service is completed, remove modified grease cap. If necessary to replace spindle
bushings, use king pin bushing tool T53T-3110-A to remove old bushings and install new bushings.
Reassemble with new service components as required.
7. If service is required on other spindle, install modified grease cap to protect spindle threads.
8. Save modified grease cap for use on other similar vehicles.
OTHER APPLICABLE ARTICLES: 82-11-8 WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information >
Technical Service Bulletins > Page 3040
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 1.0552/1.0562 inch, use the following tools: Reamer D82T-3110-A, Bushing
Remover/Installer Driver, D82T-3110-B 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information >
Technical Service Bulletins > Page 3041
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information >
Technical Service Bulletins > Page 3042
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Service and
Repair
Radius Arm: Service and Repair
EXC. 4 WHEEL DRIVE MODELS
1. Remove coil spring as described under ``Coil Spring, Replace''.
2. Remove spring lower seat from radius arm.
3. Remove radius arm and stabilizer bracket (if equipped) attaching nut and bolt from axle.
4. On all except 1983---87 E-100---350 models, remove nut, rear washer, insulator and spacer from
rear side of radius arm rear bracket.
5. On 1980 models, disconnect tie rod end.
6. On all models, remove radius arm from vehicle.
7. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Technical Service
Bulletins > Axle - Axle to Spindle Thrust Bearing Clearance
Spindle: Technical Service Bulletins Axle - Axle to Spindle Thrust Bearing Clearance
Article No. 84-22-6
AXLE - FRONT - AXLE TO SPINDLE THRUST BEARING CLEARANCE/FREEPLAY
LIGHT TRUCKS 1975 & LATER ECONOLINE
King pin thrust bearing shims are not utilized on Econoline axle and after market king pin kit shims
should not be used.
The gap between the axle and spindle interface should be measured with a feeler gauge or
freeplay measured with a dial indicator. Clearance of .050" or less is acceptable. Clearances in
excess of .050" indicate that the thrust bearing is worn down and should be replaced.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Technical Service
Bulletins > Page 3050
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.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Technical Service
Bulletins > Page 3051
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information
> Service and Repair
Stabilizer Bar: Service and Repair
1. Disconnect both ends of stabilizer bar from link assembly on I-beam bracket.
2. On 1986---87 F-350 models equipped with Dana 60 Monobeam axle, remove nuts, washers and
bolts securing links to mounting brackets.
3. Remove stabilizer bar attaching bolts and the stabilizer bar. On 1980---87 F-150 4 4 and Bronco
models, the coil spring must be removed to facilitate removal of the stabilizer bar mounting bracket.
4. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Rear
Suspension Spring ( Coil / Leaf ): Service and Repair Rear
E-100---350
1. Raise rear of vehicle and support at frame. Support axle with a suitable jack.
2. Disconnect shock absorbers from lower mountings.
3. Remove 2 U-bolts and the U-bolt plate.
4. On E-100---150 models, lower axle assembly and remove upper and lower rear shackle bolts,
then pull rear shackle assembly from bracket and spring. Remove spring mounting nut and bolt,
then lower spring assembly from vehicle.
5. On E-250---350 models, lower axle assembly and remove spring front bolt from hanger. Remove
2 attaching bolts from rear of spring, then lower spring assembly from vehicle.
6. On all models, reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Rear > Page 3059
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Air Shock Absorber
Suspension Strut / Shock Absorber: Service and Repair Front Air Shock Absorber
1. Disconnect shock absorber from upper mounting.
2. Disconnect shock absorber from lower mounting, then compress shock and remove from
vehicle.
3. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Air Shock Absorber > Page 3064
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Adjustments
Wheel Bearing: Adjustments
EXCEPT 4 WHEEL DRIVE MODELS
1. Remove wheel and tire assembly, disc brake caliper and pads, dust cap, locknut, adjusting nut,
washer and cotter pin.
2. Tighten wheel adjusting nut to 22-25 ft. lbs. while rotating disc brake rotor in opposite direction.
3. Back off wheel retention nut 1/8 turn and install retainer and cotter pin without any additional
movement of nut.
4. Reinstall dust cap, caliper, pads and tire and wheel assembly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Adjustments > Page 3068
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Technical Service Bulletins > Recalls for Axle Nut: > NHTSA82V104000 > Oct > 82 > recall 82V104000: Rear Axle Nut
Inspection
Axle Nut: Recalls recall 82V104000: Rear Axle Nut Inspection
ON CERTAIN VEHICLES, THE LOCK WEDGES USED TO SECURE THE AXLE BEARING NUTS
TO THE AXLE HOUSING MAY FALL OUT OF POSITION, ALLOWING THE NUT TO LOOSEN.
THE NUT ON THE LEFT SIDE MAY FALL OFF, ALLOWING MOVEMENT OF THE AXLE SHAFT.
THE DEALER WILL REPLACE DEFECTIVE LOCK WEDGES WITH AN IMPROVED VERSION.
WHEEL BEARINGS WILL BE INSPECTED AND ADJUSTED OR REPLACED, IF NECESSARY.
VEHICLE DESCRIPTION: LIGHT TRUCKS WITH DANA FULL-FLOATING REAR AXLES.
SYSTEM: POWER TRAIN; REAR AXLE ASSEMBLY. CONSEQUENCES OF DEFECT: THIS
COULD RESULT IN PARTIAL LOSS OF BRAKING ACTION OR PARTIAL OR TOTAL
SEPARATION OF THE LEFT REAR WHEEL AND BRAKE ASSEMBLY.IN EITHER CASE, LOSS
OF VEHICLE CONTROL AND AN ACCIDENT COULD FOLLOW.
1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK F250 1982 FORD
TRUCK F350 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK F250
1983 FORD TRUCK F350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > NHTSA82V104000 > Oct > 82 > recall
82V104000: Rear Axle Nut Inspection
Axle Nut: All Technical Service Bulletins recall 82V104000: Rear Axle Nut Inspection
ON CERTAIN VEHICLES, THE LOCK WEDGES USED TO SECURE THE AXLE BEARING NUTS
TO THE AXLE HOUSING MAY FALL OUT OF POSITION, ALLOWING THE NUT TO LOOSEN.
THE NUT ON THE LEFT SIDE MAY FALL OFF, ALLOWING MOVEMENT OF THE AXLE SHAFT.
THE DEALER WILL REPLACE DEFECTIVE LOCK WEDGES WITH AN IMPROVED VERSION.
WHEEL BEARINGS WILL BE INSPECTED AND ADJUSTED OR REPLACED, IF NECESSARY.
VEHICLE DESCRIPTION: LIGHT TRUCKS WITH DANA FULL-FLOATING REAR AXLES.
SYSTEM: POWER TRAIN; REAR AXLE ASSEMBLY. CONSEQUENCES OF DEFECT: THIS
COULD RESULT IN PARTIAL LOSS OF BRAKING ACTION OR PARTIAL OR TOTAL
SEPARATION OF THE LEFT REAR WHEEL AND BRAKE ASSEMBLY.IN EITHER CASE, LOSS
OF VEHICLE CONTROL AND AN ACCIDENT COULD FOLLOW.
1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK F250 1982 FORD
TRUCK F350 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK F250
1983 FORD TRUCK F350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear
Tires: Customer Interest Tires - Front Outside Edge Wear
Article No. 85-19-16
TIRE WEAR - FRONT - OUTSIDE EDGE
LIGHT TRUCK 1976-86 E100-150
Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by
excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15
can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit
contains complete instructions for modifying the front radius arms and mounting a metal adjusting
cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch
along two sides of the cam to the lower flange of the radius arm.
Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5
degrees. Increasing caster more than 3 degrees is not recommended since this may cause
complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased
on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built
into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of
each axle.
Three other significant factors may also contribute to outboard shoulder wear. They are excessive
toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After
any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to
extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life.
PART NUMBER PART NAME CLASS
E5TZ-3K064-A Kit Caster Adjustment C
OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME:
4.6 Hrs.
OPERATION: 3001A TIME:
0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear
Tires: All Technical Service Bulletins Tires - Front Outside Edge Wear
Article No. 85-19-16
TIRE WEAR - FRONT - OUTSIDE EDGE
LIGHT TRUCK 1976-86 E100-150
Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by
excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15
can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit
contains complete instructions for modifying the front radius arms and mounting a metal adjusting
cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch
along two sides of the cam to the lower flange of the radius arm.
Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5
degrees. Increasing caster more than 3 degrees is not recommended since this may cause
complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased
on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built
into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of
each axle.
Three other significant factors may also contribute to outboard shoulder wear. They are excessive
toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After
any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to
extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life.
PART NUMBER PART NAME CLASS
E5TZ-3K064-A Kit Caster Adjustment C
OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME:
4.6 Hrs.
OPERATION: 3001A TIME:
0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 841919 > Sep > 84 > Steering - Pull/Drift Diagnostic
Procedures
Tires: All Technical Service Bulletins Steering - Pull/Drift Diagnostic Procedures
Article No. 84-19-19
STEERING PULL/DRIFT/ROADABILITY - DIAGNOSTIC PROCEDURES
LIGHT TRUCKS 1980-84 F100-350, BRONCO, ECONOLINE
Section 19 of the 1983 and 1984 Light Truck Shop Manuals provides procedures to resolve most
roadability concerns experienced to date. These procedures can be applied to any 1980 and later
model light trucks.
When servicing 4 wheel drive vehicles with limited slip front axles, front tire circumference is the
most probable cause if the pull is only present when the hubs are locked. Installing the two most
evenly matched tires on the front axle should resolve the concern.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 841919 > Sep > 84 > Steering - Pull/Drift Diagnostic Procedures
Tires: All Technical Service Bulletins Steering - Pull/Drift Diagnostic Procedures
Article No. 84-19-19
STEERING PULL/DRIFT/ROADABILITY - DIAGNOSTIC PROCEDURES
LIGHT TRUCKS 1980-84 F100-350, BRONCO, ECONOLINE
Section 19 of the 1983 and 1984 Light Truck Shop Manuals provides procedures to resolve most
roadability concerns experienced to date. These procedures can be applied to any 1980 and later
model light trucks.
When servicing 4 wheel drive vehicles with limited slip front axles, front tire circumference is the
most probable cause if the pull is only present when the hubs are locked. Installing the two most
evenly matched tires on the front axle should resolve the concern.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Adjustments
Wheel Bearing: Adjustments
EXCEPT 4 WHEEL DRIVE MODELS
1. Remove wheel and tire assembly, disc brake caliper and pads, dust cap, locknut, adjusting nut,
washer and cotter pin.
2. Tighten wheel adjusting nut to 22-25 ft. lbs. while rotating disc brake rotor in opposite direction.
3. Back off wheel retention nut 1/8 turn and install retainer and cotter pin without any additional
movement of nut.
4. Reinstall dust cap, caliper, pads and tire and wheel assembly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Adjustments > Page 3109
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Technical Service Bulletins > Recalls for Axle Nut: > NHTSA82V104000 > Oct > 82 > recall 82V104000: Rear Axle Nut
Inspection
Axle Nut: Recalls recall 82V104000: Rear Axle Nut Inspection
ON CERTAIN VEHICLES, THE LOCK WEDGES USED TO SECURE THE AXLE BEARING NUTS
TO THE AXLE HOUSING MAY FALL OUT OF POSITION, ALLOWING THE NUT TO LOOSEN.
THE NUT ON THE LEFT SIDE MAY FALL OFF, ALLOWING MOVEMENT OF THE AXLE SHAFT.
THE DEALER WILL REPLACE DEFECTIVE LOCK WEDGES WITH AN IMPROVED VERSION.
WHEEL BEARINGS WILL BE INSPECTED AND ADJUSTED OR REPLACED, IF NECESSARY.
VEHICLE DESCRIPTION: LIGHT TRUCKS WITH DANA FULL-FLOATING REAR AXLES.
SYSTEM: POWER TRAIN; REAR AXLE ASSEMBLY. CONSEQUENCES OF DEFECT: THIS
COULD RESULT IN PARTIAL LOSS OF BRAKING ACTION OR PARTIAL OR TOTAL
SEPARATION OF THE LEFT REAR WHEEL AND BRAKE ASSEMBLY.IN EITHER CASE, LOSS
OF VEHICLE CONTROL AND AN ACCIDENT COULD FOLLOW.
1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK F250 1982 FORD
TRUCK F350 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK F250
1983 FORD TRUCK F350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Axle Nut: > NHTSA82V104000 > Oct > 82 > recall
82V104000: Rear Axle Nut Inspection
Axle Nut: All Technical Service Bulletins recall 82V104000: Rear Axle Nut Inspection
ON CERTAIN VEHICLES, THE LOCK WEDGES USED TO SECURE THE AXLE BEARING NUTS
TO THE AXLE HOUSING MAY FALL OUT OF POSITION, ALLOWING THE NUT TO LOOSEN.
THE NUT ON THE LEFT SIDE MAY FALL OFF, ALLOWING MOVEMENT OF THE AXLE SHAFT.
THE DEALER WILL REPLACE DEFECTIVE LOCK WEDGES WITH AN IMPROVED VERSION.
WHEEL BEARINGS WILL BE INSPECTED AND ADJUSTED OR REPLACED, IF NECESSARY.
VEHICLE DESCRIPTION: LIGHT TRUCKS WITH DANA FULL-FLOATING REAR AXLES.
SYSTEM: POWER TRAIN; REAR AXLE ASSEMBLY. CONSEQUENCES OF DEFECT: THIS
COULD RESULT IN PARTIAL LOSS OF BRAKING ACTION OR PARTIAL OR TOTAL
SEPARATION OF THE LEFT REAR WHEEL AND BRAKE ASSEMBLY.IN EITHER CASE, LOSS
OF VEHICLE CONTROL AND AN ACCIDENT COULD FOLLOW.
1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK F250 1982 FORD
TRUCK F350 1983 FORD TRUCK E250 1983 FORD TRUCK E350 1983 FORD TRUCK F250
1983 FORD TRUCK F350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure
Wheel Fastener: Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure
Article No. 98-5A-4
^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP
^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP
FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA
1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97
PROBE 1994-97 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI
1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII
1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI
1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE
LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO
II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER
1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR
ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or
unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and
installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly
torqued wheel lug nuts may cause:
^ Brake vibration
^ Distortion of the wheel hub
^ Distortion of the brake rotor
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 3128
^ 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 3129
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Air Door Actuator
Air Door Actuator / Motor: Locations Air Door Actuator
Rear Middle Of Plenum
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Air Door Actuator > Page 3136
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service
Bulletins > A/C Aspirator Drain Tube Kit - Service Only
Aspirator: Technical Service Bulletins A/C Aspirator Drain Tube Kit - Service Only
Article No. 84-18-21-S
A/C ASPIRATOR DRAIN TUBE KIT - SERVICE ONLY - ECONOLINE VEHICLES BUILT FROM
1975 THROUGH FEBRUARY, 1984
LIGHT TRUCKS 1975-84 ECONOLINE
Part number E4UYZ-19858-D shown in Article No. 84-18-21 is incorrect. The correct part umber is
E4UZ- 19858-B. Please cross reference this to TSB No. 84-18, page 33.
PART NUMBER PART NAME CLASS
E4UZ-19858-B A/C Aspirator Drain Tube Kit B
OTHER APPLICABLE ARTICLES: Article No. 84-18-21 WARRANTY STATUS: "INFORMATION
ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Blower Motor: > 851019 > May > 85 > A/C Blower Motor - Inoperative
Blower Motor: All Technical Service Bulletins A/C Blower Motor - Inoperative
Article No. 85-10-19
AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER
LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES
When operating the A/C system for long periods of time with the blower motor set on high, the
solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the
heat build-up. A revised fuse holder is released to resolve the subject concern.
The following procedure should be performed:
1. Check fuse for damage (solder melted at end of fuse).
2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat
build-up).
3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for
inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in
Steps 1 and 2 continue with Step 4.
4. Disconnect battery ground cable.
5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel.
6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close
to the fuse panel as possible and remove the fuse holders from the fuse panel.
7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Blower Motor: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page
3149
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 851019 > May > 85 > A/C Blower Motor - Inoperative
Blower Motor: Customer Interest A/C Blower Motor - Inoperative
Article No. 85-10-19
AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER
LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES
When operating the A/C system for long periods of time with the blower motor set on high, the
solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the
heat build-up. A revised fuse holder is released to resolve the subject concern.
The following procedure should be performed:
1. Check fuse for damage (solder melted at end of fuse).
2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat
build-up).
3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for
inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in
Steps 1 and 2 continue with Step 4.
4. Disconnect battery ground cable.
5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel.
6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close
to the fuse panel as possible and remove the fuse holders from the fuse panel.
7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 3155
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Page 3156
Blower Motor: Locations
Attached To RH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Page 3157
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations
Blower Motor Resistor: Locations
Part Of Blower Motor Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Auxiliary Blower Switch
Blower Motor Switch: Locations Auxiliary Blower Switch
RH Side Of Function Control
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Auxiliary Blower Switch > Page 3165
Blower Motor Switch: Locations Front Blower Switch
LH Side Of Control Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Technical Service Bulletins > A/C - Warner Compressor Clutch Replacement
Compressor Clutch: Technical Service Bulletins A/C - Warner Compressor Clutch Replacement
Article No. 85-4-3
AIR CONDITIONING - REPLACEMENT OF WARNER A/C COMPRESSOR CLUTCH ASSEMBLY
FORD 1980-84 ALL
LINCOLN-MERCURY 1980-84 ALL
LIGHT TRUCK 1980-84 ALL LIGHT TRUCKS
When existing stock of 1980-84 Warner Electric A/C compressor clutch hub and pulley parts is
exhausted, it will be necessary to replace the entire clutch assembly, including the field coil, with
current Ford manufactured clutch parts. Replacement of the Warner field coil is necessary because
it is not compatible with the Ford clutch parts. The Warner field coil will continue to be available for
replacement on Warner clutch assemblies.
NOTE: Never intermix clutch parts from different manufacturers. Refer to the Master Parts Catalog
for part numbers and vehicle application.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3179
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3180
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3181
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3182
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3183
Figure 25
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3184
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3185
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3186
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3187
Figure 29
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3188
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3189
Figure 30
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3190
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3191
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3192
Figure 31
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Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 3193
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.
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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)
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Bulletins > Customer Interest: > 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.
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Bulletins > Customer Interest: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 3199
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.
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Figure 8
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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).
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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.
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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)
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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.
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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
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Bulletins > All Technical Service Bulletins: > 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
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Page 3211
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
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Page 3212
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).
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Page 3213
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
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Page 3214
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.
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Page 3215
Figure 25
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Bulletins > All Technical Service Bulletins: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment >
Page 3216
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.
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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.)
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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.
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Figure 29
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Page 3220
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.
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Figure 30
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Page 3222
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.
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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.
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Figure 31
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Page 3225
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.
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Page 3226
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)
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Bulletins > All Technical Service Bulletins: > 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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment
> Page 3231
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment
> Page 3232
Figure 8
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment
> Page 3233
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment
> Page 3234
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment
> Page 3235
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment
> Page 3236
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment
> Page 3237
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition
Catalytic Converter: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3243
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3244
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3245
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3246
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3247
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3248
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3249
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3255
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3256
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3257
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3258
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3259
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3260
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Evaporator Case: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3261
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications 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.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into
Passenger Compartment
Evaporator Drain Tube: Customer Interest A/C - Condensate Leakage Into Passenger
Compartment
Article No. 86-9-14
A/C CONDENSATE LEAKS INTO PASSENGER COMPARTMENT - VEHICLES BUILT PRIOR TO
MARCH 1986
LIGHT TRUCK 1975-86 ECONOLINE
When a vehicle is operated under conditions of extremely high humidity with the Function Selector
Lever in the "NORM A/C" position and the blower switch in "HI", some evaporator condensate,
instead of draining out of the vehicle, is being blown through the ducts and registers and into the
passenger compartment.
Condensate from the evaporator core exceeds the amount which can be drawn off through the
drain tube in the evaporator case. As a result, the excess condensate can be pulled away from the
drain tube and picked up in the air stream created by the blower motor. It is then expelled through
the A/C registers. To correct the condition, one or more of the following service procedures should
be initiated in the sequence listed. They are to be initiated on a customer complaint basis. Vehicles
built prior to March, 1984 will continue to be serviced, as required, by all of the procedures covered
in TSB 85-11-16 in addition to the procedures provided in this article. Complaints requiring service
on vehicles built from March, 1984 to March, 1986 will be handled by following the sequence of
procedures in this article.
NOTE: Operation of the blower at a lower speed than HI will allow accumulated condensate to
drain out the drain tube. Therefore, operation of the blower below HI where possible, or periodic
reduction of the blower speed from HI, will significantly reduce moisture accumulation. Also, when
comfort will allow, operation of the air conditioner in MAX A/C rather than NORM A/C will reduce
condensate accumulation by reducing the humidity entering the vehicle.
SERVICE PROCEDURE:
1. The sealing and leak checking procedures previously published in TSB 85-11-16, dated 6/3/85,
must have already been performed, or should now be performed before proceeding with the added
service operations covered in this article.
2. Replace the evaporator check valve and drain tube assembly (including the 90~ formed drain
tube and check valve) with a new check valve and drain tube assembly.
3. If replacement of the evaporator drain tube assembly does not correct the condensate leak, add
a separate drain hole in the blower housing as outlined under "Addition of Drain to Blower,
Housing".
4. If the condition still persists, install a locally fabricated moisture coalescer screen as outlined
under "Addition of Coalescer Screen to Evaporator Assembly".
Sealing and Leak Checking Per TSB 85-11-16
1. Using TSB 85-11-16 as a guide, confirm that the sealing operations described have been
effectively accomplished.
2. If sealing is missing, apply it to the surfaces indicated in the TSB.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into
Passenger Compartment > Page 3270
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into
Passenger Compartment > Page 3271
Figure 8
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into
Passenger Compartment > Page 3272
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into
Passenger Compartment > Page 3273
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into
Passenger Compartment > Page 3274
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into
Passenger Compartment > Page 3275
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.
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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 3276
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
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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)
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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 3281
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).
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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 3282
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.
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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 3283
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.
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Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water
Leaks to Interior > Page 3284
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
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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 3285
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
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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 3286
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.
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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 3287
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).
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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 3288
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
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Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water
Leaks to Interior > Page 3289
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
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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.
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Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate
Leakage Into Passenger Compartment > Page 3295
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.
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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 3296
Figure 8
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate
Leakage Into Passenger Compartment > Page 3297
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).
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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 3298
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.
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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 3299
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate
Leakage Into Passenger Compartment > Page 3300
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate
Leakage Into Passenger Compartment > Page 3301
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator
Housing - Water Leaks to Interior
Evaporator Drain Tube: All Technical Service Bulletins A/C Evaporator Housing - Water Leaks to
Interior
Article No. 85-11-16
AIR CONDITIONING - INADEQUATE DRAINAGE FROM EVAPORATOR HOUSING
LIGHT TRUCK 1975-85 ECONOLINE
During conditions of high humidity and high blower operation, evaporator condensate leaks into the
passenger compartment from the A/C blower housing, blower housing to evaporator housing flange
and/or the A/C register outlets.
The fundamental cause of this leakage is that the blower is located downstream of the evaporator
core (draw through system), resulting in a negative housing pressure with respect to ambient.
During this condition of negative pressure, air flow can be drawn through the drain tube into the
housing opposing the flow of condensate drainage out of the drain tube. Also, air leakage into the
housing because of insufficient drain tube sealing can cause this concern.
Due to improper condensate drainage, water can accumulate in the bottom of the temperature
blend door frame assembly and spill into the blower housing. If this condition occurs, insufficient
sealing at the blower housing to evaporator housing flange and at the blower scroll cover to blower
housing may allow leakage into the passenger compartment from these areas.
An accumulation of water in the blower housing may result in water being blown through the
register ducts and register outlets.
PROCEDURE:
Install the new check valve drain tube assembly which completely shuts off air flow through the
drain tube, due to the negative pressure, yet allows water to drain freely under all housing negative
pressures encountered in service.
Due to manufacturing variations of evaporator assemblies, some units are more susceptible to
condensate accumulation and will require rework of the blend door frame and may necessitate
resealing the lower housing flange.
The following three drain tube systems may be reworked as outlined in the following paragraphs.
Figure 18
Econoline Vehicles with (Production) Aspirator Drain Tube Built March 1984 through September
1984
Drain Tube Replacement (Refer to Figure 18)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator
Housing - Water Leaks to Interior > Page 3306
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator
Housing - Water Leaks to Interior > Page 3307
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator
Housing - Water Leaks to Interior > Page 3308
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator
Housing - Water Leaks to Interior > Page 3309
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator
Housing - Water Leaks to Interior > Page 3310
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator
Housing - Water Leaks to Interior > Page 3311
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator
Housing - Water Leaks to Interior > Page 3312
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator
Housing - Water Leaks to Interior > Page 3313
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator
Housing - Water Leaks to Interior > Page 3314
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Locations
Evaporator Temperature Sensor / Switch: Locations
A/C EVAPORATOR DE-ICING SWITCH
RH Dash Panel Attached To Evaporator
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Locations
Heater Control Valve: Locations
Rear Of Engine Compartment
Above RH Rear Side Of Engine
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Heater Core - Leakage Diagnostic Tips
Heater Core: Technical Service Bulletins Heater Core - Leakage Diagnostic Tips
Article No. 85-8-2
HEATER CORE - LEAK - DIAGNOSTIC TIPS
FORD ALL
LINCOLN-MERCURY ALL
LIGHT TRUCK ALL
Good heater cores are being returned through the parts return system coded as leaking.
Complaints of leaking may be caused by an inadequate seal between the heater hose and the
heater core tubes allowing coolant to follow the tube to the heater core, leak into the passenger
compartment and appear as a leaking heater core.
When diagnosing a suspect heater core leak, inspect the hose to heater core tube attachment to
assure the connection is not leaking. If a leaking connection is found, correct the leak. If the
connection appears not to be leaking, leak test the heater core before removing it from the vehicle
using the following procedure:
HEATER CORE LEAK TEST
Pressure Test 1.
Drain the coolant from the cooling system.
2. Disconnect the heater hoses from the heater core tubes.
3. Install a short piece of heater hose (approximately 4 inches long) on each heater core tube.
Figure 1
4. Fill the heater core and hoses with water and install plug BT-7422-B and adapter BT-7422-A
from Rotunda model 021-00012 or equivalent in the hose ends (Figure 1). Secure the hoses, plug
and adapter with hose clamps.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Heater Core - Leakage Diagnostic Tips > Page 3325
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Heater Core - Leakage Diagnostic Tips > Page 3326
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 3327
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 3328
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical
Service Bulletins > Heater Damper Door - Service Part Information
Housing Assembly HVAC: Technical Service Bulletins Heater Damper Door - Service Part
Information
AIR CONDITIONING-HEATER DAMPER DOOR AND HOUSING ASSEMBLY-SERVICE PART
INFORMATION
Article No. 89-11-9
Figure 1
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical
Service Bulletins > Heater Damper Door - Service Part Information > Page 3333
Figure 2
LIGHT TRUCK: 1975-84 ECONOLINE
ISSUE: The air conditioning/heater damper door and housing assembly to service 1975 through
1984 Econolines are no longer available for service. A new design air conditioning/heater damper
door and housing assembly replaces the old design. The new assembly can be used on older
Econolines if a few minor changes are made.
ACTION: If service is required on an older Econoline, use the new air conditioning/heater damper
door and housing assembly. Refer to the following procedure for service installation details.
1. Trim the flange off three (3) sides of the door frame as shown in Figure 1.
2. Position the template shown in Figure 2 on the door frame.
3. Drill two (2) holes in the bottom of the door frame for attaching it to the housing assembly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical
Service Bulletins > Heater Damper Door - Service Part Information > Page 3334
4. Attach the door frame to the housing assembly with two (2) 1/4 inch (6.35 mm) screws.
PART NUMBER PART NAME CLASS
E4UZ-18D293-A A/C-Heater Damper Door And C
Housing
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2610
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement
Technical Service Bulletin # 98-12-5 Date: 980622
A/C - Filtering Refrigerant After Compressor Replacement
Article No. 98-12-5
06/22/98
AIR CONDITIONING - FILTERING REFRIGERANT
AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS
FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS
1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86
CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92
MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII
1995-98-MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150,
F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98
EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER
1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to revise the Service Procedure and to update
the model years.
ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the
refrigerant system cleaned to remove any debris or contaminants that may be present to prevent
damage to the replacement compressor.
ACTION
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3339
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3340
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3341
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3342
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3343
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3344
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3345
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3346
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3347
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Without Rear A/C .................................................................................................................................
....................................................................... 3.5 lbs
With Rear A/C ......................................................................................................................................
..................................................................... 4.25 lbs
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 3350
Refrigerant: Fluid Type Specifications
Type .....................................................................................................................................................
............................................... Refrigerant 12 (R-12) Ford Part Number .............................................
........................................................................................................................................
D4AZ-19B519-A
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement
Technical Service Bulletin # 98-12-5 Date: 980622
A/C - Filtering Refrigerant After Compressor Replacement
Article No. 98-12-5
06/22/98
AIR CONDITIONING - FILTERING REFRIGERANT
AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS
FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS
1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86
CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92
MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII
1995-98-MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150,
F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98
EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER
1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to revise the Service Procedure and to update
the model years.
ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the
refrigerant system cleaned to remove any debris or contaminants that may be present to prevent
damage to the replacement compressor.
ACTION
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3355
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3356
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3357
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Refrigerant Oil System Capacity .........................................................................................................
....................................................................... 10.5 oz
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 3362
Refrigerant Oil: Fluid Type Specifications
Compressor ................................................................................................................... 500 viscosity
(C9AZ-19557-B or Motorcraft VN-2 or equivalent)
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Auxiliary Blower Switch
Blower Motor Switch: Locations Auxiliary Blower Switch
RH Side Of Function Control
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Auxiliary Blower Switch > Page 3368
Blower Motor Switch: Locations Front Blower Switch
LH Side Of Control Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Locations
Evaporator Temperature Sensor / Switch: Locations
A/C EVAPORATOR DE-ICING SWITCH
RH Dash Panel Attached To Evaporator
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations >
Temperature Selector Vacuum Connection Block
Vacuum Harness HVAC: Locations Temperature Selector Vacuum Connection Block
Behind I/P Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations >
Temperature Selector Vacuum Connection Block > Page 3376
Vacuum Harness HVAC: Locations Function Control Vacuum Connection Block
Behind I/P Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations >
Page 3377
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Tank <--> [Vacuum Reservoir HVAC] > Component
Information > Description and Operation
Vacuum Tank: Description and Operation
Fig. 37 Vacuum reservoirs
The vacuum reservoir, Fig. 37, used on some vehicles, acts as an accumulator and prevents
sudden drops or rapid fluctuations in a vacuum signal during acceleration. If vacuum in the
reservoir leaks more than 1/2 inch Hg in 1 minute, the reservoir is defective and must be replaced.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information >
Locations
Vacuum Solenoid Valve HVAC: Locations
AUXILIARY HEATER VACUUM SOLENOID VALVE
Rear Of Engine
RH Side Of Engine Compartment
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 3390
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 3391
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 3392
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 3393
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 3394
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 3395
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Seat/Shoulder Belts - General Service Information > Page 3396
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations
Seat Belt Buckle Switch: Locations
Part Of Driver's Seat Belt
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Technical
Service Bulletins > Safety Belt - Tongue Cover Now Available
Seat Belt Latch: Technical Service Bulletins Safety Belt - Tongue Cover Now Available
SAFETY BELT - TONGUE COVER SERVICE PART
AVAILABILITY
Article No. 88-25-2
FORD: 1974-88 ALL
LINCOLN-MERCURY: 1974-88 ALL
LIGHT-TRUCK: 1974-88 ALL
MEDIUM/HEAVY: 1974-88
ISSUE: The safety belt tongue cover is now available for service. It is no longer necessary to
replace the entire safety belt assembly in the event a buckle and tongue cover requires service.
ACTION: No corrective action is required. Refer to the following application chart for the correct
service part number.
NOTE: THE SAFETY BELT TONGUE COVERS ARE SERVICED IN A NEUTRAL COLOR AND
MUST BE PAINTED TO MATCH.
SAFETY BELT TONGUE COVER APPLICATION CHART MODEL YEAR
VEHICLE SERVICE PART NO.
1986-88 Taurus/Sable E7DZ-54612A64-A
1974-88 All Other Vehicles E7FZ-61612A64-A
PART NUMBER PART NAME CLASS
E7DZ-54612A64-A Safety Belt Tongue Cover Package of 4
BM
E7FZ-61612A64-A Safety Belt Tongue Cover Package of 4
B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 1050, 1051, 1800
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations
Seat Belt Buckle Switch: Locations
Part Of Driver's Seat Belt
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > System Information >
Technical Service Bulletins > Antitheft Devices - Installation Precautions
Antitheft and Alarm Systems: Technical Service Bulletins Antitheft Devices - Installation
Precautions
Article No. 86-3-9
ANTI-THEFT DEVICES (AFTER MARKET) - INSTALLATION/ OPERATING PRECAUTIONS ON
VEHICLES EQUIPPED WITH ELECTRONIC ENGINE CONTROLS (EEC)
FORD 1978-86 ALL
LINCOLN-MERCURY 1978-86 ALL
LIGHT TRUCK 1981-86 ALL
NOTE: This article is being republished in its entirety to include 1986 models.
Installation of "AfterMarket" anti-theft devices such as fuel shutoff and ignition defeating devices
may cause no starts, hard starting, stalls, or damage to vehicle components on Ford vehicles
equipped with electronic engine controls. Possible damage caused by these devices can result
from the following situations:
1. Fuel shutoff devices - Attempting to start the vehicle without disarming this device may cause the
fuel injectors to run dry and overheat, which will lead to failure of the injectors.
2. Ignition defeating devices which ground the ignition/tachometer lead - Attempting to start the
vehicle without disarming may result in ignition coil failure.
Figure 13
In addition, care must be taken when routing underhood after market wiring (see Figure 13 for
proper precautions), in order to avoid electromagnetic interference with electronic engine controls.
The following precautions must be observed:
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > System Information >
Technical Service Bulletins > Antitheft Devices - Installation Precautions > Page 3413
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio Power Boost Switch > Component Information > Locations
Radio Power Boost Switch: Locations
Attached To RH Cowl
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Locations
Radio/Stereo Noise Filter: Locations
Below Voltage Regulator
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Radio Power Boost Switch > Component Information > Locations
Radio Power Boost Switch: Locations
Attached To RH Cowl
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations
Trailer Lighting Relay: Locations
LH Rear Fender Below LH Taillight
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component
Information > Technical Service Bulletins > Body - Spot Weld Marks On Side Panels
Lower Side Moulding / Trim: Technical Service Bulletins Body - Spot Weld Marks On Side Panels
Article No. 85-6-15
SHEET METAL - SPOT WELD MARKS ON BODY SIDE PANELS
LIGHT TRUCK 1980-85 ECONOLINE
Spot weld marks along the lower body side panels at the character line of Econoline vehicles may
affect appearance or customer satisfaction.
This condition can be resolved with the installation of a 24mm wide adhesively attached body side
molding kit now available as a service kit. The moldings are applied along the character line from
the rear of the front fender to the rear of the vehicle. This service only kit is pre-cut, and requires
only cleaning the surface of all wax and dirt, peeling the plastic backing from the molding and
applying the molding in the designated area. The body side molding kit is designed to fit both the
124 inch and 138 inch wheelbase units with either sliding or cargo side doors.
PART NUMBER PART NAME CLASS
E5UZ-2221048-A Body Side Molding Kit BA
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Frame Rivet Replacement with Bolts Service Tip > Page 3440
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 8871033088 > Mar > 88 > Power Door
Locks - Are Inoperative
Power Door Lock Actuator: Customer Interest Power Door Locks - Are Inoperative
LOCKS - POWER - ROD RETAINER CLIP ASSEMBLY BREAKS OR DISENGAGES
POWER DOOR LOCKS - INOPERATIVE - ROD RETAINER CLIP BREAKS OR DISENGAGES
Article No. 88-7-1
FORD: 1980-82 GRANADA 1980-83 FAIRMONT 1980-88 MUSTANG, THUNDERBIRD, CROWN
VICTORIA 1983-86 LTD 1984-85 ESCORT 1984-88 TEMPO 1986-88 TAURUS
LINCOLN-MERCURY: 1980 MONARCH
1980-81 LINCOLN 1980-83 ZEPHYR, MARK VI 1980-86 CAPRI 1980-88 COUGAR, GRAND
MARQUIS 1982-88 CONTINENTAL, LINCOLN TOWN CAR 1983-86 MARQUIS 1984-85 LYNX
1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1980-88 ECONOLINE 1981-88 F SERIES 1985-86 RANGER, BRONCO II
ISSUE: Inoperative power door locks maybe caused by a broken or disengaged lock rod retainer
clip assembly. The broken or disengaged retainer clip allows the power lock actuator to disconnect
from the actuator rod.
ACTION: To correct this, install a new lock rod retainer clip assembly made out of stronger
material. Refer to the following removal and installation procedure.
1. Remove door trim panel and water shield.
2. Remove broken or disengaged retainer assembly and replace it with new retainer assembly
(E8AZ-5421952-A).
NOTE: To prevent damage, make sure the latch assembly is supported from behind before tapping
the retainer assembly into the latch assembly. Be careful not to bend the lever of the latch.
3. In some cases, the latch assembly may have to be removed to provide enough space to install
the retainer assembly. Refer to Section 44 of the appropriate Shop Manual for latch removal and
installation procedures.
4. Reinstall water shield and door trim panel.
PART NUMBER PART NAME CLASS
E8AZ-5421952-A Retainer Clip Assembly BG
OTHER APPLICABLE ARTICLES: 85-12-3 WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 8871033088 > Mar > 88 >
Power Door Locks - Are Inoperative
Power Door Lock Actuator: All Technical Service Bulletins Power Door Locks - Are Inoperative
LOCKS - POWER - ROD RETAINER CLIP ASSEMBLY BREAKS OR DISENGAGES
POWER DOOR LOCKS - INOPERATIVE - ROD RETAINER CLIP BREAKS OR DISENGAGES
Article No. 88-7-1
FORD: 1980-82 GRANADA 1980-83 FAIRMONT 1980-88 MUSTANG, THUNDERBIRD, CROWN
VICTORIA 1983-86 LTD 1984-85 ESCORT 1984-88 TEMPO 1986-88 TAURUS
LINCOLN-MERCURY: 1980 MONARCH
1980-81 LINCOLN 1980-83 ZEPHYR, MARK VI 1980-86 CAPRI 1980-88 COUGAR, GRAND
MARQUIS 1982-88 CONTINENTAL, LINCOLN TOWN CAR 1983-86 MARQUIS 1984-85 LYNX
1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1980-88 ECONOLINE 1981-88 F SERIES 1985-86 RANGER, BRONCO II
ISSUE: Inoperative power door locks maybe caused by a broken or disengaged lock rod retainer
clip assembly. The broken or disengaged retainer clip allows the power lock actuator to disconnect
from the actuator rod.
ACTION: To correct this, install a new lock rod retainer clip assembly made out of stronger
material. Refer to the following removal and installation procedure.
1. Remove door trim panel and water shield.
2. Remove broken or disengaged retainer assembly and replace it with new retainer assembly
(E8AZ-5421952-A).
NOTE: To prevent damage, make sure the latch assembly is supported from behind before tapping
the retainer assembly into the latch assembly. Be careful not to bend the lever of the latch.
3. In some cases, the latch assembly may have to be removed to provide enough space to install
the retainer assembly. Refer to Section 44 of the appropriate Shop Manual for latch removal and
installation procedures.
4. Reinstall water shield and door trim panel.
PART NUMBER PART NAME CLASS
E8AZ-5421952-A Retainer Clip Assembly BG
OTHER APPLICABLE ARTICLES: 85-12-3 WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Technical Service Bulletins > Page 3456
Power Door Lock Actuator: Locations
Inside Doors
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Locations
Power Door Lock Relay: Locations
Lower LH Cowl Near Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal
Paint: Technical Service Bulletins Paint - Iron Particle Removal
Article No. 95-6-1
03/27/95
^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION
^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN
DISCOLORATION OR ETCHING
FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP
1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994-95
ASPIRE 1995 CONTOUR
LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN
CAR 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER
1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after
BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and
after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after
WINDSTAR
MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B
SERIES, L SERIES 1986 and after CARGO SERIES
ISSUE: Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail
shipments, combustion engines, jet engines, body shops, etc. These particles
mechanically/magnetically bond to vehicles' painted surfaces. Moisture and temperature combine
with the particles to create a chemical reaction. The reaction causes the particles to corrode and
enter into the physical paint film.
ACTION: To remove these particles/contaminants, USE ONLY the following procedure. The
procedure must be performed before any buffing, polishing, color sanding or refinishing is
attempted. The materials in this procedure are alkaline, acidic and neutral. They must be used in
the specified order.
CAUTION:
ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR
UNSATISFACTORY REPAIR AND MAY RESULT IN
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3465
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3466
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3467
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3468
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3469
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3470
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3471
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3472
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3473
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3474
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3475
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3476
Paint: Technical Service Bulletins Paint - Cosmetic Surface Service Procedures
Article No. 84-3-3
PAINT - COSMETIC SURFACE SERVICE PROCEDURES
FORD ALL CAR LINES - ALL MODEL YEARS
LINCOLN-MERCURY ALL CAR LINES - ALL MODEL YEARS
LIGHT TRUCKS ALL SERIES - ALL MODEL YEARS
The cosmetic paint surface service procedures outlined below are reprinted from Article Number
82-3-3 dated February 18, 1982. Many of these procedures and techniques described have been
incorporated along with several other helpful procedures in a video tape which is now available.
This video tape describes paint and soft facia service procedures developed by Ford Motor
Company Assembly plants to correct minor concerns. After seeing the video tape and with practice,
a technician or body shop employee should be able to do the following:
^ Remove most minor dings and dents (without filling and repainting), by using special metal
massaging service tools.
^ Remove hood and deck depressions without filling and repainting.
^ Remove trapped dirt particles and still preserve the original paint finish.
^ Service minor scratches that do not cut through into the prime or metal.
^ Service orange peel without repainting.
^ Service sags and runs without repainting.
^ Remove surface stains with a heat gun.
^ Make soft facia services on many punctures and tears in plastic parts without replacement.
^ Service damaged abrasion resistant coating.
^ Properly paint over E-coating.
The video tape is titled, "Cosmetic Paint and Surface Repairs" and is available in 3/4 inch Umatic
UMC, Order Number 4651-025; or 1/2 inch VHS, Order Number 4651-025.
For ordering information refer to the Ford Service Training Aids Catalog or write to:
Ford Service Publications Post Office Box 07150 Detroit, Michigan 48207
Exterior paint surface damage or imperfections of a nature where the prime coat does not show
can, in most instances, be restored without repainting. The restoration of gloss and luster after the
condition has been removed is made possible by new and improved service materials and
procedures. The following procedure is applicable to surface conditions such as dirt particles,
orange peel, runs, sags, industrial fallout stains, swirl marks, light scratches and other minor
imperfections. Usually, these conditions are localized and it is not necessary to restore the entire
panel. However, in a case such as dirt particles or scratches in several localized areas, it is
recommended that the entire panel be restored to maintain a uniform appearance.
FIGURE 5
Preparation
Before starting the service, the affected surface must be clean and dry. Mask off adjacent panels,
mouldings, stripes and character lines as required (Figure 5). Where applicable, eye protection,
face mask and a belt buckle cover should be worn.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3477
Service Procedure
The basic concept of the procedure is to remove the defect condition, and then restore the finish to
an acceptable appearance. As a general guideline, remember that sanding marks are removed
with rubbing compound and the swirl marks evident after buffing are removed by polishing. As an
example, light scratches or small dirt particles can be removed with a power buffer and medium
buffing compound followed by polishing. Deeper scratches, heavy dirt particles or orange peel must
be wet sanded, buffed with compound to remove the sanding marks and then polished to remove
the swirl marks from the buffing operation.
It is suggested with initial service attempts, that technicians develop a learning cycle by picking a
small service area and first try polishing, then buffing and finally wet sanding to remove the
condition. When you have determined which method is appropriate, proceed with the remaining
area to be serviced and then restore the finish as required. The following outlines the complete
procedure and required materials.
FIGURE 6
Polishing
For removal of very minor scratches, swirl marks and/or to restore luster to a dull finish.
Apply a small amount of 3M Final Glaze to the affected panel (Figure 6) and using a suitable
electric or air powered polish/buffing wheel (2000 max. rpm) and a 3M Superbuff 2 + 2 Pad, polish
the affected area until all swirl marks are gone and desired luster is obtained. When polishing, keep
the pad flat against the surface. Do not bear down, the weight of the buffer is sufficient. Add Final
Glaze sparingly as needed. Compound
For removal of light scratches, small dirt particles, minor grind marks and sanding marks.
FIGURE 7
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3478
FIGURE 8
Apply 3M Superduty Rubbing Compound (medium) to the panel and using a clean 2 + 2 pad on the
wheel (as noted above) spread the compound evenly and buff the surface until the condition is
removed; or in the case of a sanded area, the sanding marks are gone and the luster is restored to
an acceptable level for polishing (Figure 7 and Figure 8). When buffing, keep the wheel flat to the
surface using light to moderate pressure and long even strokes. Periodically check the finish and
add compound as required. When buffing is complete, polish the panel as described above.
Sanding
For removal of severe conditions such as heavy dirt particles, deep scratches and orange peel.
This wet sanding procedure utilizes 3M Ultra Fine Imperial Wetordry Color Sanding Paper to
facilitate removal of surface damage. The Ultra Fine paper cuts quickly leaving a uniform finish that
requires a minimum of buffing to restore the luster.
FIGURE 9
1. Soak the 3M Imperial Wetordry Paper and a 3M Imperial Wetordry Sponge Pad thoroughly in
clean water and wrap the paper around the pad as shown in Figure 9.
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3479
FIGURE 10
2. Using a clean sponge, wet the area to be sanded. It is essential that the paper be kept wet as
sanding proceeds (Figure 10).
FIGURE 11
3. Wet sand the affected area with light even pressure on the pad with back and forth strokes (not
circular). Do a small area at a time (Figure 11).
FIGURE 12
4. Frequently dip the pad and paper in water to wash off sanding residue (Figure 12).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3480
FIGURE 13
5. Frequently flood or squeegee off the affected surface to check depth of cut and to see if the
defect is removed. The amount of paint surface that is being sanded can be judged as the area
dulls (Figure 13).
FIGURE 14
6. Water wash the affected area to determine if all surface defects have been removed. Note the
uniform dull appearance of an evenly sanded panel (Figure 14). If the surface is not uniform, lightly
resand the area.
FIGURE 15
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3481
7. Wash and squeegee off the panel and check to assure that all defects are removed and sanding
is complete. Then proceed with the buffing and polish procedures to restore the luster to the finish.
8. Figure 15 shows a hood panel which has been sanded, buffed and polished on one section to
illustrate the effectiveness of the procedure.
Runs and Sags
The service of runs and sags in nonmetallic paint is covered in the previously released training
publication "The Wet Look." This procedure, which consists of shaving the run or sag flush with a
commercial single edge razor blade, sanding with a hard block and then compounding, can now be
improved by finishing the service with Final Glaze. It is recommended that minor sags and runs be
wet sanded with 600 grit paper. If it is necessary to shave them off with a razor blade, first dull the
corners with sandpaper to avoid scratching the adjacent panel finish.
PART NUMBER PART NAME CLASS
05528 3M Imperial Wetordry Sponge Pad
02021 3M Imperial Wetordry Color
Sanding Paper
05955 3M Superduty Rubbing
Compound
05957 3M Superduty Paste Compound
(if preferred)
05701 3M Superbuff 2 + 2 Pad
05710 3M Superbuff Adaptor (if req'd)
05988 3M Final Glaze
02024 3M Wetordry Tri-M-ite Paper 600 Grit
05519 3M Sanding Block
7" Polisher/Buffer Air or Electric Razor Blade - Industrial Single Edge
OTHER APPLICABLE ARTICLES: 82-3-3 WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: SPP6282 TIME:
One Panel 0.4 Hr. - Each additional 0.2 Hr. MATERIAL ALLOWANCE: $.75 per panel DLR.
CODING: Basic Part No. As applicable
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3482
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.
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Bulletins > Paint - Iron Particle Removal > Page 3483
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3484
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3485
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 3486
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations
Lower LH Cowl Near Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and
Inspection
Brake Switch (Cruise Control): Testing and Inspection
Perform this test only when brake application will not disconnect the speed control system.
1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If
more than 6 lbs. is required, check brake pedal actuation and stop lamp switch.
2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch.
3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire
w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire
w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983
F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87
Aerostar.
4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on
1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on
1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco
II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5
volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair
Clutch Switch: Service and Repair
1. Remove bracket mounting screw(s).
2. Disconnect electrical connector and remove switch and bracket assembly.
3. Remove switch from bracket.
4. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations
Cruise Control Module: Locations
LH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 3501
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations
Cruise Control Servo: Locations
RH Rear Of Engine Compartment
RH Side Of Engine Compartment
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 3505
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 3506
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair
Cruise Control Servo Cable: Service and Repair
1. Remove servo assembly, then discard cable.
2. Attach new actuator cable to servo assembly.
3. Install servo assembly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations
Cruise Control Switch: Locations
On Steering Wheel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 3513
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 3514
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information > Locations
Cruise Control Vacuum Vent Solenoid: Locations
Top Of Brake Pedal Support
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component
Information > Locations
Cruise Control Module: Locations
LH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component
Information > Locations > Page 3522
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Testing and Inspection
Brake Switch (Cruise Control): Testing and Inspection
Perform this test only when brake application will not disconnect the speed control system.
1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If
more than 6 lbs. is required, check brake pedal actuation and stop lamp switch.
2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch.
3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire
w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire
w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983
F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87
Aerostar.
4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on
1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on
1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco
II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5
volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Service and Repair
Clutch Switch: Service and Repair
1. Remove bracket mounting screw(s).
2. Disconnect electrical connector and remove switch and bracket assembly.
3. Remove switch from bracket.
4. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations
Cruise Control Switch: Locations
On Steering Wheel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations > Page 3533
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations > Page 3534
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Testing and Inspection
Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Testing and
Inspection
Vacuum Vent Valve: Testing and Inspection
1. Disconnect vacuum hose from the servo that leads to the dump valve.
2. Connect a hand vacuum pump to the hose, and draw vacuum. If vacuum cannot be obtained,
the hose or dump valve is leaking, and should be replaced.
3. Step on brake pedal. The vacuum should be released. If not, adjust or replace the dump valve.
2.5 inches of Hg is minimum vacuum for normal
servo operation. The vacuum source is a hose attached to a 5/16 inch engine vacuum fitting port
on all except 6.9 diesel. On the 6.9 diesel, the vacuum source is the vacuum reservoir ``Vac'' port.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Testing and
Inspection > Page 3541
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information >
Testing and Inspection
Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Ammeter Gauge > Component Information
> Testing and Inspection
Ammeter Gauge: Testing and Inspection
The ammeter is an instrument used to indicate current flow into and out of the battery. When
electrical accessories in the vehicle draw more current than the alternator can supply, current flows
from the battery and the ammeter indicates a discharge ( - ) condition. When electrical loads of the
vehicle are less than alternator output, current is available to charge the battery, and the ammeter
indicates a charge (+) condition. If battery is fully charged, the voltage regulator reduces alternator
output to meet only immediate vehicle electrical loads. When this happens, ammeter reads zero.
Fig. 1 Conventional type ammeter
CONVENTIONAL AMMETER
A conventional ammeter must be connected between the battery and alternator in order to indicate
current flow. This type ammeter, Fig. 1, consists of a frame to which a permanent magnet is
attached. The frame also supports an armature and pointer assembly. Current in this system flows
from the alternator through the ammeter, then to the battery or from the battery through the
ammeter into the vehicle electrical system, depending on vehicle operating conditions. When no
current flows through the ammeter, the magnet holds the pointer armature so that the pointer
stands at the center of the dial. When current passes in either direction through the ammeter, the
resulting magnetic field attracts the armature away from the effect of the permanent magnet, thus
giving a reading proportional to the strength of the current flowing.
Troubleshooting When the ammeter apparently fails to register correctly, there may be trouble in
the wiring which connects the ammeter to the alternator and battery or in the alternator or battery
itself. To check the connections, first tighten the two terminal posts on the back of the ammeter.
Then, following each wire from the ammeter, tighten all connections on the ignition switch, battery
and alternator. Chafed, burned or broken insulation can be found by following each ammeter wire
from end to end. All wires with chafed, burned or broken insulation should be repaired or replaced.
After this is done, and all connections are tightened, connect the battery cable and turn on the
ignition switch. The needle should point slightly to the discharge ( - ) side. Start the engine and run
slightly above idling speed. The needle should move slowly to the charge side (+). If the pointer
does not move as indicated, the ammeter is out of order and should be replaced.
SHUNT TYPE AMMETER The shunt type ammeter is actually a specifically calibrated voltmeter. It
is connected to read voltage drop across a resistance wire (shunt) between the battery and
alternator. The shunt is located either in the vehicle wiring or within the ammeter itself. When
voltage is higher at the alternator end of the shunt, the meter indicates a charge (+) condition.
When voltage is higher at the battery end of the shunt, the meter indicates a discharge ( - )
condition. When voltage is equal at both ends of the shunt, the meter reads zero. Troubleshooting
Ammeter accuracy can be determined by comparing reading with an ammeter of known accuracy.
1. With engine stopped and ignition switch in RUN position, switch on headlamps and heater fan.
Meter should indicate a discharge ( - ) condition.
2. If ammeter pointer does not move, check ammeter terminals for proper connection and check for
open circuit in wiring harness. If connections and wiring harness are satisfactory, ammeter is
defective.
3. If ammeter indicates a charge (+) condition, wiring harness connections are reversed at
ammeter.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Locations
Audible Warning Device: Locations
LH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection
Clock: Testing and Inspection
Regulation of electric clocks is accomplished automatically by resetting the time. If the clock is
running fast, the action of turning the hands back to correct the time will automatically cause the
clock to run slightly slower. If the clock is running slow, the action of turning the hands forward to
correct the time will automatically cause the clock to run slightly faster (10 to 15 seconds daily). A
lockout feature prevents the clock regulator mechanism from being reset more than once per wind
cycle, regardless of the number of times the time is reset. After the clock rewinds, if the time is then
reset, automatic regulation will take place. If a clock varies over 10 minutes per day, it will never
adjust properly and must be repaired or replaced.
WINDING CLOCK WHEN CONNECTING BATTERY OR CLOCK WIRING The clock requires
special attention when reconnecting a battery that has been disconnected for any reason, a clock
that has been disconnected, or when replacing a blown clock fuse. It is very important that the
initial wind be fully made. The procedure is as follows:
1. Make sure that all other instruments and lights are turned off.
2. Connect positive cable to battery.
3. Before connecting the negative cable, press the terminal to its post on the battery. Immediately
afterward, strike the terminal against the battery post to see if there is a spark. If there is a spark,
allow the clock to run down until it stops ticking, and repeat as above until there is no spark. Then
immediately make the permanent connection before the clock can again run down. The clock will
run down in approximately two minutes.
4. Reset clock after all connections have been made. The foregoing procedure should also be
followed when reconnecting the clock after it has been disconnected, or if it has stopped because
of a blown fuse. Be sure to disconnect battery before installing a new fuse.
TROUBLESHOOTING If clock does not run, check for blown ``clock'' fuse. If fuse is blown, check
for short in wiring. If fuse is not blown, check for open circuit. With an electric clock, the most
frequent cause of clock fuse blowing is voltage at the clock which will prevent a complete wind and
allow clock contacts to remain closed. This may be caused by any of the following: discharged
battery, corrosion on contact surface of battery terminals, loose connections at battery terminals, at
junction block, at fuse clips, or at terminal connection of clock. Therefore, if in reconnecting battery
or clock it is noted that the clock is not ticking, always check for blown fuse, or examine the circuits
at the points indicated above to determine and correct the cause.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations
Door Switch: Locations
Inside Driver's Door
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module >
Component Information > Locations
Fuel Distance/Mileage Module: Locations
Near ECA Under RH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component
Information > Service and Repair
Instrument Cluster / Carrier: Service and Repair
Fig. 8 Instrument Cluster
E-100---350
1. Disconnect battery ground cable.
2. Remove steering column shroud.
3. On models equipped with tilt steering column, loosen column-to-band C support to provide
sufficient clearance for cluster removal.
4. On all models, remove 7 instrument cluster-to-instrument panel attaching screws.
5. Pull cluster back from panel and disconnect speedometer cable. It may be necessary to
disconnect speedometer cable from transmission to provide access to the quick disconnect on the
cluster.
6. Disconnect electrical connector from printed circuit board and remove cluster from vehicle, Fig.
9.
7. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings
Odometer: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings
SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND
ODOMETER READINGS
Article No. 89-2-7
FORD: 1989 AND PRIOR ALL CAR LINES
LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES
LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES
ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle
components or systems. The information in this TSB article is intended to assist technicians in
speedometer/odometer concern diagnosis.
ACTION: Use the following supplemental information below to assist in speedometer/odometer
diagnostics.
OPERATION
A mechanical analog speedometer displays vehicle speed and the odometer displays total distance
traveled. The speedometer/odometer assembly is cable driven by either a transmission or a
transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with
respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed
so that all are identical and have no error in the speedometer head.
Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the
speedometer/odometer. An electronic signal is sent from a speed sensor to the digital
speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle,
similar to a cable.
Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio
and speedometer/odometer drive and driven gears.
TIRES
Improper tire rolling radius and inflation pressure, temperature and size may contribute to
inaccurate system readings. System accuracy testing should be performed after the tires are set at
the correct pressure as shown on the safety compliance certification label. The tires should be
warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a
constant speed within the posted speed limit.
AXLE/TRANSAXLE RATIO
The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or
check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios
are available, but usually are not a concern when dealing with speedometer/odometer concerns
unless the gear ratio has been changed.
WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS
THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS
The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case
and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel
drive vehicles have several driven gears with various numbers of teeth available to correct input to
the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears
for correction.
GENERAL DESCRIPTION
The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance
traveled. Ford Motor vehicles are well within those limits.
The speed indication is biased high, except on police vehicles with certified calibration
speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the
actual speed. This is intended to protect the consumer against violating speed laws. Most customer
concerns are related to speedometers reading too high at true speeds between 50 MPH and 65
MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10%
greater than true speed.
The speedometer head is an instrument which processes information sent to it by the rotating
speedometer cable. If the system components send the
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 3568
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil
pressure gauge and a sending unit which are connected in series. The sending unit consists of a
diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm
actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil
pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge,
in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor
is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge
reading.
TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions
included with the tester.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator >
Component Information > Testing and Inspection
Oil Pressure Warning Lamp/Indicator: Testing and Inspection
Many trucks utilize a warning light on the instrument panel in place of the conventional dash
indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is
wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil
pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on,
the warning light circuit is energized and the circuit is completed through the closed contacts in the
pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm,
opening the contacts, thereby breaking the circuit and putting out the light.
TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If
it does not light, disconnect the wire from the engine unit and ground the wire to the frame or
cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the
bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the
engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight
and properly grounded, it should be removed and a new one installed. (The presence of sealing
compound on the threads of the engine unit will cause a poor ground). If the warning light remains
lit when it normally should be out, replace the engine unit before proceeding further to determine
the cause for a low pressure indication. The warning light will sometimes light up or flicker when the
engine is idling, even though the oil pressure is adequate. However, the light should go out when
the engine speed is increased.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Distance/Mileage Module > Component Information > Locations
Fuel Distance/Mileage Module: Locations
Near ECA Under RH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations
Door Switch: Locations
Inside Driver's Door
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Cable > Component
Information > Testing and Inspection
Speedometer Cable: Testing and Inspection
The following material covers only that service on speedometers which is feasible to perform.
Repairs on the units themselves are not included as they require special tools and extreme care
when making repairs and adjustments that only an experienced speedometer mechanic should
attempt. The speedometer has two main parts, the speedometer head and the speedometer drive
cable. When the speedometer fails to indicate speed or mileage, the cable or cable housing is
probably broken. On vehicles are equipped with speed control, there is a speed sensor attached to
the transmission. This is used to sense the revolutions of cable assembly and to regulate speed
control.
SPEEDOMETER CABLE Most cables are broken due to lack of lubrication, or a sharp bend or kink
in the housing. A cable might break because of the speedometer head mechanism binds. In such
cases, the speedometer head should be repaired or replaced before a new cable or housing is
installed. A ``jumpy'' pointer condition, together with a scraping noise, is due, in most instances, to
a dry or kinked speedometer cable. The kinked cable rubs on the housing and winds up, slowing
down the pointer. The cable then unwinds and the pointer ``jumps.'' To check for kinks, remove the
cable, lay it on a flat surface and twist one end with the fingers. If it turns over smoothly the cable is
not kinked. But if part of the cable flops over as it is twisted, the cable is kinked and should be
replaced.
LUBRICATION The speedometer cable should be lubricated with special cable lubricant. Fill the
ferrule on the upper end of the housing with the cable lubricant. Insert the cable in the housing,
starting at the upper end. Turn the cable around carefully while feeding it into the housing. Repeat
filling the ferrule except for the last six inches of cable. Too much lubricant at this point may cause
the lubricant to work into the speedometer head.
INSTALLING CABLE During installation, if the cable sticks when inserted in the housing and will
not go through, the housing is damaged inside or kinked. Be sure to check the housing from one
end to the other. Straighten any sharp bends by relocating clamps or elbows. Replace housing if it
is badly kinked or broken. Position the cable and housing so that they lead into the head as straight
as possible. Check the new cable for kinks before installing it. Use wide, sweeping, gradual curves
where the cable comes out of the transmission and connects to the head so the cable will not be
damaged during installation. Arrange the housing so it does not lean against the engine because
heat from the engine may dry out the lubricant. If inspection indicates that the cable and housing
are in good condition, yet pointer action is erratic, check the speedometer head for possible
binding. The speedometer drive pinion should also be checked. If the pinion is dry or its teeth are
stripped, the speedometer may not register properly.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings
Speedometer Head: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings
SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND
ODOMETER READINGS
Article No. 89-2-7
FORD: 1989 AND PRIOR ALL CAR LINES
LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES
LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES
ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle
components or systems. The information in this TSB article is intended to assist technicians in
speedometer/odometer concern diagnosis.
ACTION: Use the following supplemental information below to assist in speedometer/odometer
diagnostics.
OPERATION
A mechanical analog speedometer displays vehicle speed and the odometer displays total distance
traveled. The speedometer/odometer assembly is cable driven by either a transmission or a
transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with
respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed
so that all are identical and have no error in the speedometer head.
Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the
speedometer/odometer. An electronic signal is sent from a speed sensor to the digital
speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle,
similar to a cable.
Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio
and speedometer/odometer drive and driven gears.
TIRES
Improper tire rolling radius and inflation pressure, temperature and size may contribute to
inaccurate system readings. System accuracy testing should be performed after the tires are set at
the correct pressure as shown on the safety compliance certification label. The tires should be
warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a
constant speed within the posted speed limit.
AXLE/TRANSAXLE RATIO
The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or
check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios
are available, but usually are not a concern when dealing with speedometer/odometer concerns
unless the gear ratio has been changed.
WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS
THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS
The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case
and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel
drive vehicles have several driven gears with various numbers of teeth available to correct input to
the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears
for correction.
GENERAL DESCRIPTION
The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance
traveled. Ford Motor vehicles are well within those limits.
The speed indication is biased high, except on police vehicles with certified calibration
speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the
actual speed. This is intended to protect the consumer against violating speed laws. Most customer
concerns are related to speedometers reading too high at true speeds between 50 MPH and 65
MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10%
greater than true speed.
The speedometer head is an instrument which processes information sent to it by the rotating
speedometer cable. If the system components send the
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 3596
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Dash Gauge Test
Temperature Gauge: Testing and Inspection Dash Gauge Test
Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble
should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by
clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the
case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of
the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type
system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable
resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which
maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is
attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip,
causing the pointer to move. As more current passes through the coil, heat increases, moving the
pointer farther. The circuit is completed through a sending unit which contains a variable resistor.
When resistance is high, less current is allowed to pass through the gauge, and the pointer moves
very little. As resistance decreases due to changing conditions in system being monitored, more
current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to
system or ground output terminals of IVR, as damage to system components or wiring circuits may
result.
DASH GAUGE TEST
1. Disconnect battery ground cable and remove gauge from vehicle.
2. Connect ohmmeter between gauge terminals and read coil winding resistance.
3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current
of ohmmeter causes a temperature rise in gauge coil windings.
4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Dash Gauge Test > Page 3601
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator,
Engine Cooling > Component Information > Testing and Inspection
Temperature Warning Lamp/Indicator: Testing and Inspection
A bimetal temperature switch located in the cylinder head control the operation of a temperature
indicator light with a red lens. If the engine cooling system is not functioning properly and coolant
temperature exceeds a predetermined value, the warning light will illuminate.
TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a
burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when
the engine is running, check the wiring between light and switch for a ground, defective
temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is
functioning properly, a wire which is connected to the ground terminal of the ignition switch is
tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground
terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and
the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled
by the temperature switch.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information
> Testing and Inspection
Volt Meter Gauge: Testing and Inspection
The voltmeter is a gauge which measures the electrical flow from the battery to indicate whether
the battery output is within tolerances. The voltmeter reading can range from 13.5---14.0 volts
under normal operating conditions. If an undercharge or overcharge condition is indicated for an
extended period, the battery and charging system should be checked.
TROUBLESHOOTING To check voltmeter, turn key and headlights on with engine off. Pointer
should move to 12.5 volts. If no needle movement is observed, check connections from battery to
circuit breaker. If connections are tight and meter shows no movement, check wire continuity. If
wire continuity is satisfactory, the meter is inoperative and must be replaced.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Automatic Transmission
Backup Lamp Switch: Locations Automatic Transmission
Attached To Base Of Steering Column
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Automatic Transmission > Page 3614
Backup Lamp Switch: Locations Manual Transmission
Attached To Shifter Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Automatic Transmission > Page 3615
Backup Lamp Switch: Locations 3-Speed Manual Transmission
Near Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations
Brake Lamp: Locations
Turn/Stop/Hazard Lamps
Component Locations
Hazard Flasher ....................................................................................................................................
............................................................ LH side of I/P
Stop Light Switch .................................................................................................................................
...................................... Top of brake pedal support
Turn Signal Flasher .............................................................................................................................
........................................................... LH side of I/P
Turn/Hazard Switch
.........................................................................................................................................................
Upper LH side of steering column
Connector C110
............................................................................................................................................................
LH side of rear frame crossmember
Connector C308
.................................................................................................................................................... At LH
side of rear frame crossmember ...
Connector C309
.................................................................................................................................................... At
RH side of rear frame crossmember ...
Connector C310 ..................................................................................................................................
..................................... Upper LH side of dash panel
Connector C315
............................................................................................................................................................
LH side of I/P near steering column
Connector C727 ..................................................................................................................................
.................................... Lower LH side of dash panel
Connector C914
.........................................................................................................................................................
Below fuel tank select valve solenoid
Connector C921
.............................................................................................................................................................
LH rear under frame, near fuel tank
Ground G203
..........................................................................................................................................................
Behind I/P on steering column support .
Ground G501
.......................................................................................................................................................
Attached to LH fender above marker light
Ground G502
.......................................................................................................................................................
Attached to RH fender above marker light
Ground G601 .......................................................................................................................................
.................................... Lower LH rear quarter panel
Ground G603 .......................................................................................................................................
................................... Lower RH rear quarter panel
Several images for locations are given at the Lighting And Horns System level under the various
connector numbers. See: Locations/Connector Locations
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Page 3619
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Page 3620
Brake Lamp: Description and Operation
How The Circuit Works
Stop Lights
Current flows through Fuse 8 to the rear Turn/Stop Lights when the Stop Light Switch is closed.
The same rear lights are used for Stop and Turn Lights (controlled by turn switch).
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
Brake Light Switch: Locations
Top Of Brake Pedal Support
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 3624
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations
Door Switch: Locations
Inside Driver's Door
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Locations
Hazard Warning Lamps: Locations
Turn/Stop/Hazard Lamps
Component Locations
Hazard Flasher ....................................................................................................................................
............................................................ LH side of I/P
Stop Light Switch .................................................................................................................................
...................................... Top of brake pedal support
Turn Signal Flasher .............................................................................................................................
........................................................... LH side of I/P
Turn/Hazard Switch
.........................................................................................................................................................
Upper LH side of steering column
Connector C110
............................................................................................................................................................
LH side of rear frame crossmember
Connector C308
.................................................................................................................................................... At LH
side of rear frame crossmember ...
Connector C309
.................................................................................................................................................... At
RH side of rear frame crossmember ...
Connector C310 ..................................................................................................................................
..................................... Upper LH side of dash panel
Connector C315
............................................................................................................................................................
LH side of I/P near steering column
Connector C727 ..................................................................................................................................
.................................... Lower LH side of dash panel
Connector C914
.........................................................................................................................................................
Below fuel tank select valve solenoid
Connector C921
.............................................................................................................................................................
LH rear under frame, near fuel tank
Ground G203
..........................................................................................................................................................
Behind I/P on steering column support .
Ground G501
.......................................................................................................................................................
Attached to LH fender above marker light
Ground G502
.......................................................................................................................................................
Attached to RH fender above marker light
Ground G601 .......................................................................................................................................
.................................... Lower LH rear quarter panel
Ground G603 .......................................................................................................................................
................................... Lower RH rear quarter panel
Several images for locations are given at the Lighting And Horns System level under the various
connector numbers. See: Locations/Connector Locations
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Locations > Page
3631
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Locations > Page
3632
Hazard Warning Lamps: Description and Operation
How The Circuit Works
Hazard Lights
Current flows through Fuse 8 to the Turn Lights and Turn Indicators when the hazard switch is
pulled out.
The turn switch sends current to both the RH and LH Turn Lights at the same time.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations
Headlamp Dimmer Switch: Locations
LH Floor Board
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and
Repair
Headlamp Switch: Service and Repair
Fig. 5 Light Switch
E-100---350
1. Disconnect battery ground cable.
2. Remove knob and shaft assembly by depressing release button on switch housing and pulling
straight out.
3. Remove bezel or mounting nut from switch, Fig. 4.
4. Disconnect electrical connector from switch and remove switch from vehicle.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Horn Relay: Locations
Horn Relay Location
Under LH Side Of I/P.
Under LH Side Of I/P, With Speed Control
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 3644
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 3645
Horn Relay: Testing and Inspection
Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 3646
Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 3647
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations
License Plate Lamp: Locations
Exterior Lamps
Component Locations
Button Connectors ...............................................................................................................................
................................ Rear doors and rear door jamb
Light Switch .........................................................................................................................................
................................... I/P, to left of steering column
Connector C110
............................................................................................................................................................
LH side of rear frame crossmember
Connector C303 ..................................................................................................................................
.................................... Lower LH side of dash panel
Connector C308
.................................................................................................................................................... At LH
side of rear frame crossmember ...
Connector C309
.................................................................................................................................................... At
RH side of rear frame crossmember ...
Connector C310 ..................................................................................................................................
..................................... Upper LH side of dash panel
Connector C411 ..................................................................................................................................
.................................... LH side of I/P at light switch
Ground G501
.......................................................................................................................................................
Attached to LH fender above marker light
Ground G502
.......................................................................................................................................................
Attached to RH fender above marker light
Ground G601 .......................................................................................................................................
.................................... Lower LH rear quarter panel
Ground G603 .......................................................................................................................................
.................................... Lower RH rear quarter panel
Ground G954 .......................................................................................................................................
............................. LH rear door, above license lights
Several images for locations are given at the Lighting And Horns System level under the various
connector numbers. See: Locations/Connector Locations
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations > Page 3651
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations
Marker Lamp: Locations
Exterior Lamps
Component Locations
Button Connectors ...............................................................................................................................
................................ Rear doors and rear door jamb
Light Switch .........................................................................................................................................
................................... I/P, to left of steering column
Connector C110
............................................................................................................................................................
LH side of rear frame crossmember
Connector C303 ..................................................................................................................................
.................................... Lower LH side of dash panel
Connector C308
.................................................................................................................................................... At LH
side of rear frame crossmember ...
Connector C309
.................................................................................................................................................... At
RH side of rear frame crossmember ...
Connector C310 ..................................................................................................................................
..................................... Upper LH side of dash panel
Connector C411 ..................................................................................................................................
.................................... LH side of I/P at light switch
Ground G501
.......................................................................................................................................................
Attached to LH fender above marker light
Ground G502
.......................................................................................................................................................
Attached to RH fender above marker light
Ground G601 .......................................................................................................................................
.................................... Lower LH rear quarter panel
Ground G603 .......................................................................................................................................
.................................... Lower RH rear quarter panel
Ground G954 .......................................................................................................................................
............................. LH rear door, above license lights
Several images for locations are given at the Lighting And Horns System level under the various
connector numbers. See: Locations/Connector Locations
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 3655
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 3656
Marker Lamp: Description and Operation
How The Circuit Works
Turn Lights
With the Ignition Switch in RUN, current can flow through Fuse 11, the Turn Signal Flasher,
Turn/Hazard Switch, and on to the Turn Lights and Turn Indicators.
The turn switch sends the power to either the LH or RH Turn Lights.
Stop Lights
Current flows through Fuse 8 to the rear Turn/Stop Lights when the Stop Light Switch is closed.
The same rear lights are used for Stop and Turn Lights (controlled by turn switch).
Hazard Lights
Current flows through Fuse 8 to the Turn Lights and Turn Indicators when the hazard switch is
pulled out.
The turn switch sends current to both the RH and LH Turn Lights at the same time.
For Troubleshooting hints, refer to Marker Lamp Testing and Inspection procedures. See: Testing
and Inspection
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Backup
Lamps
Marker Lamp: Testing and Inspection Backup Lamps
Troubleshooting Hints
No Backup Lights Work Check Fuse 11 by operating the Turn Lights.
- Separate C305 With gearshift in REVERSE, check continuity through PRNDL or Backup Switch,
at BK/R wires.
One Backup Lamp Will Not Work Check bulb.
- Check socket for corrosion.
- Check voltage at socket hot pin.
- Check continuity to ground.
Backup Lights Stay ON Check adjustment, or replace switch.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Backup
Lamps > Page 3659
Marker Lamp: Testing and Inspection Headlights/Marker/Park/License
Troubleshooting Hints
No Headlights/Park Lights ON Check for voltage at R/Y wire of Dimmer Switch. If bad, check continuity of wire and Light Switch
- Check continuity of Dimmer Switch. Replace if bad
No Hi And Lo Beam On One Side Make sure ground connection on that side is clean and tight
No Exterior Lights Look for frayed or damaged wires, or loose connections
- Make sure C411 is tight.
- Check for voltage at BK/O wire of Light Switch. If bad, check harness back to Battery.
- If Instrument Illumination lights work, check continuity of BR wire in harness.
- If no instrument lights work, check continuity of Light Switch.
One Light Does Not Work Check bulb.
- Check for frayed or damaged wires, or loose connections.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Backup
Lamps > Page 3660
Marker Lamp: Testing and Inspection Turn/Stop/Hazard Lamps
Troubleshooting Hints
Hazard Flasher Doesn't Work Check Fuse 8 by operating Stop Lights.
- Check voltage at Hazard Flasher R/W wire.
- Replace Hazard Flasher.
- Check voltage at C315.
- Replace Turn/Hazard Switch.
Turn Indicators Don't Work Check Fuse 11 by operating Backup Lights.
- Replace Turn Signal Flasher.
- Check voltage of Turn Signal Flasher O/Y wire.
- Repair or replace Turn/Hazard Switch.
No Front Or Rear Lights Check ground points are tight and not corroded.
One Turn Light Not Operating Check for burned-out bulb.
- Check voltage and ground at bulb socket.
- Check for frayed or damaged wires.
- Check that connectors are not corroded.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations
Parking Lamp: Locations
Exterior Lamps
Component Locations
Button Connectors ...............................................................................................................................
................................ Rear doors and rear door jamb
Light Switch .........................................................................................................................................
................................... I/P, to left of steering column
Connector C110
............................................................................................................................................................
LH side of rear frame crossmember
Connector C303 ..................................................................................................................................
.................................... Lower LH side of dash panel
Connector C308
.................................................................................................................................................... At LH
side of rear frame crossmember ...
Connector C309
.................................................................................................................................................... At
RH side of rear frame crossmember ...
Connector C310 ..................................................................................................................................
..................................... Upper LH side of dash panel
Connector C411 ..................................................................................................................................
.................................... LH side of I/P at light switch
Ground G501
.......................................................................................................................................................
Attached to LH fender above marker light
Ground G502
.......................................................................................................................................................
Attached to RH fender above marker light
Ground G601 .......................................................................................................................................
.................................... Lower LH rear quarter panel
Ground G603 .......................................................................................................................................
.................................... Lower RH rear quarter panel
Ground G954 .......................................................................................................................................
............................. LH rear door, above license lights
Several images for locations are given at the Lighting And Horns System level under the various
connector numbers. See: Locations/Connector Locations
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Page 3664
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Horn Relay: Locations
Horn Relay Location
Under LH Side Of I/P.
Under LH Side Of I/P, With Speed Control
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 3669
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 3670
Horn Relay: Testing and Inspection
Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 3671
Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 3672
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Trailer Lighting Relay: Locations
LH Rear Fender Below LH Taillight
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Automatic Transmission
Backup Lamp Switch: Locations Automatic Transmission
Attached To Base Of Steering Column
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Automatic Transmission > Page 3681
Backup Lamp Switch: Locations Manual Transmission
Attached To Shifter Assembly
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Automatic Transmission > Page 3682
Backup Lamp Switch: Locations 3-Speed Manual Transmission
Near Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
Top Of Brake Pedal Support
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 3686
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations
Door Switch: Locations
Inside Driver's Door
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations
Headlamp Dimmer Switch: Locations
LH Floor Board
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Service and Repair
Headlamp Switch: Service and Repair
Fig. 5 Light Switch
E-100---350
1. Disconnect battery ground cable.
2. Remove knob and shaft assembly by depressing release button on switch housing and pulling
straight out.
3. Remove bezel or mounting nut from switch, Fig. 4.
4. Disconnect electrical connector from switch and remove switch from vehicle.
5. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Upper LH Side Of Steering Column
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations > Page 3699
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations
Trailer Lighting Relay: Locations
LH Rear Fender Below LH Taillight
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations
> Turn Flasher
Turn Signal Flasher: Locations Turn Flasher
Behind LH Side Of I/P
HAZARD WARNING: Behind LH side Of I/P, On Fuse Panel TURN SIGNAL: Behind LH Side Of
I/P, On Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations
> Turn Flasher > Page 3711
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations
Turn Signal Switch: Locations
Upper LH Side Of Steering Column
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 3715
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations
Power Window Relay: Locations
Lower LH Cowl Near Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations
Power Window Motor: Locations
Behind Trim Panels, Below Windows
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations
Power Window Relay: Locations
Lower LH Cowl Near Fuse Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > Customer Interest: > 8852 > Mar > 88 > Manual Vent Windows - Difficult to Open
Window Glass: Customer Interest Manual Vent Windows - Difficult to Open
GLASS - MANUAL VENT WINDOWS HARD TO OPEN
Article No. 88-5-2
FORD: 1980-88 CROWN VICTORIA 1981-86 THUNDERBIRD 1981-87 ESCORT 1984-86 LTD
LINCOLN-MERCURY: 1980-88 GRAND MARQUIS
1981-86 LYNX, COUGAR 1984-86 MARQUIS
LIGHT TRUCK: 1980-88 E-SERIES, F-SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II
1986-88 AEROSTAR
ISSUE: Hard to open pivoting type vent windows may be caused by the glass sticking to the
weatherstrip on the division bar. The weatherstrip is often pulled out of the division bar when this
condition is present.
FIGURE 1
ACTION: To correct this, apply a strip of clear pressure sensitive tape on the inside vertical edge of
the vent window glass, Figure 1.
PART NUMBER PART NAME CLASS
E8AZ-19627-A Clear Pressure Sensitive B
Tape
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 880502A - Both vent windows TIME:
0.3 Hr. DLR. CODING: Basic Part No. 7021402 Code:
41
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 8852 > Mar > 88 > Manual Vent Windows - Difficult to Open
Window Glass: All Technical Service Bulletins Manual Vent Windows - Difficult to Open
GLASS - MANUAL VENT WINDOWS HARD TO OPEN
Article No. 88-5-2
FORD: 1980-88 CROWN VICTORIA 1981-86 THUNDERBIRD 1981-87 ESCORT 1984-86 LTD
LINCOLN-MERCURY: 1980-88 GRAND MARQUIS
1981-86 LYNX, COUGAR 1984-86 MARQUIS
LIGHT TRUCK: 1980-88 E-SERIES, F-SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II
1986-88 AEROSTAR
ISSUE: Hard to open pivoting type vent windows may be caused by the glass sticking to the
weatherstrip on the division bar. The weatherstrip is often pulled out of the division bar when this
condition is present.
FIGURE 1
ACTION: To correct this, apply a strip of clear pressure sensitive tape on the inside vertical edge of
the vent window glass, Figure 1.
PART NUMBER PART NAME CLASS
E8AZ-19627-A Clear Pressure Sensitive B
Tape
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 880502A - Both vent windows TIME:
0.3 Hr. DLR. CODING: Basic Part No. 7021402 Code:
41
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Window Glass: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light
Stays On
Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light
Stays On
Article No. 84-21-9
WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON
FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT
LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING
LIGHT
LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT
On some vehicles equipped with low fluid warning light, the light may stay on even when the
washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that
has not been mixed with water according to the instructions. The undiluted washer solution is
absorbed by the float resulting in the float sinking.
When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions
on the can must be followed. Mixing the concentrated washer fluid with water will stop the float
from sinking.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest: > 8398 > May > 83 > Side Window - Water Leaks
Window Seal: Customer Interest Side Window - Water Leaks
Article No. 83-9-8
LEAKS - WATER - FLIP-OUT PRIVACY GLASS SIDE WINDOWS
LIGHT TRUCKS 1982-83 ECONOLINE
Figure 7
The glass frame can be distorted by the window latch, causing leaks between the glass and frame.
The latch should be adjusted to use minimum locking effort to reduce the force on the frame.
Additionally, applying silicone rubber sealer to the glass and frame inner and outer faces (Figure 7)
will be necessary for those frames that have had this seal broken. Care must be taken when
applying this sealer to produce an acceptable finished appearance.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest: > 8398 > May > 83 > Side Window - Water Leaks > Page 3759
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: M TIME:
"Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No.
7025722 Code: 45
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 8398 > May > 83 > Side Window - Water Leaks
Window Seal: All Technical Service Bulletins Side Window - Water Leaks
Article No. 83-9-8
LEAKS - WATER - FLIP-OUT PRIVACY GLASS SIDE WINDOWS
LIGHT TRUCKS 1982-83 ECONOLINE
Figure 7
The glass frame can be distorted by the window latch, causing leaks between the glass and frame.
The latch should be adjusted to use minimum locking effort to reduce the force on the frame.
Additionally, applying silicone rubber sealer to the glass and frame inner and outer faces (Figure 7)
will be necessary for those frames that have had this seal broken. Care must be taken when
applying this sealer to produce an acceptable finished appearance.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 8398 > May > 83 > Side Window - Water Leaks > Page 3765
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION: M TIME:
"Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No.
7025722 Code: 45
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Window Seal: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light
Stays On
Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light
Stays On
Article No. 84-21-9
WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON
FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT
LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING
LIGHT
LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT
On some vehicles equipped with low fluid warning light, the light may stay on even when the
washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that
has not been mixed with water according to the instructions. The undiluted washer solution is
absorbed by the float resulting in the float sinking.
When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions
on the can must be followed. Mixing the concentrated washer fluid with water will stop the float
from sinking.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations
Wiper Control Module: Locations
Upper LH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Technical Service Bulletins > Customer Interest for Washer Fluid Level
Switch: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On
Washer Fluid Level Switch: Customer Interest Wiper/Washer - Low Fluid Warning Light Stays On
Article No. 84-21-9
WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON
FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT
LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING
LIGHT
LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT
On some vehicles equipped with low fluid warning light, the light may stay on even when the
washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that
has not been mixed with water according to the instructions. The undiluted washer solution is
absorbed by the float resulting in the float sinking.
When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions
on the can must be followed. Mixing the concentrated washer fluid with water will stop the float
from sinking.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Washer Fluid
Level Switch: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On
Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light
Stays On
Article No. 84-21-9
WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON
FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT
LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING
LIGHT
LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT
On some vehicles equipped with low fluid warning light, the light may stay on even when the
washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that
has not been mixed with water according to the instructions. The undiluted washer solution is
absorbed by the float resulting in the float sinking.
When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions
on the can must be followed. Mixing the concentrated washer fluid with water will stop the float
from sinking.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
Wiper Switch: Locations
Upper LH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 3798
Wiper Switch: Testing and Inspection
Fig. 4 Wiper Switch Continuity Test
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 3799
Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 3800
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Page 3801
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical
Service Bulletins > Customer Interest for Washer Fluid Level Switch: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid
Warning Light Stays On
Washer Fluid Level Switch: Customer Interest Wiper/Washer - Low Fluid Warning Light Stays On
Article No. 84-21-9
WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON
FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT
LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING
LIGHT
LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT
On some vehicles equipped with low fluid warning light, the light may stay on even when the
washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that
has not been mixed with water according to the instructions. The undiluted washer solution is
absorbed by the float resulting in the float sinking.
When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions
on the can must be followed. Mixing the concentrated washer fluid with water will stop the float
from sinking.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Washer Fluid Level Switch: > 84219 > Oct > 84 > Wiper/Washer - Low
Fluid Warning Light Stays On
Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light
Stays On
Article No. 84-21-9
WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON
FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT
LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING
LIGHT
LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT
On some vehicles equipped with low fluid warning light, the light may stay on even when the
washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that
has not been mixed with water according to the instructions. The undiluted washer solution is
absorbed by the float resulting in the float sinking.
When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions
on the can must be followed. Mixing the concentrated washer fluid with water will stop the float
from sinking.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations
Wiper Control Module: Locations
Upper LH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair
Wiper Gear Box: Service and Repair
1. Disconnect battery ground cable.
2. Remove both wiper arm and blade assemblies.
3. Remove cowl grille attaching screws and raise the grille slightly.
4. Disconnect windshield washer fluid hose, then remove cowl grille.
5. Remove clip securing right and left linkage and the retaining clip from wiper motor arm.
6. Remove 3 pivot body-to-cowl panel attaching screws, then the arm and pivot shaft assembly.
7. Reverse procedure to install.
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Wiper Motor - Noisy
Wiper Motor: Technical Service Bulletins Wiper Motor - Noisy
Article No. 83-22-16
WIPER MOTOR - NOISY
LIGHT TRUCKS 1975-83 ECONOLINE
Econolines with a noisy windshield wiper motor(s) may be serviced with a newly released motor
that incorporates a brush assembly that reduces motor noise.
PART NUMBER PART NAME CLASS
E3PZ-17508-A Wiper Motor A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time
Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 17508 Code:
56
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Page 3825
Wiper Motor: Locations
LH Side Of Dash Panel
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Page 3826
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Page 3827
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 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations
Wiper Switch: Locations
Upper LH Side Of I/P
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 3831
Wiper Switch: Testing and Inspection
Fig. 4 Wiper Switch Continuity Test
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 3832
Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350
Ford E 250 Van Workshop Manual (V8-460 7.5L (1982))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 3833
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.